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Cadfil Help V7.63

1. SMALL MOVE AX n Significant axis motions for axes 1 to n A value must be supplied for each axis on the machine This function holds small incremental axis motions until the value of the motion for an axis is greater than the significant axis motion specified for that axis If values of zero 0 0 are entered then all motions are output however small they may be The values entered for each axis should be in the relevant machine units If an axis is not present on the machine a value should still be entered 0 0 for example as six values are always expected If these are set to zero for active axes then there may occasionally be very small machine motions due to the numerical rounding errors associated with the generation of the path across the surface mesh Such motions will not add to the accuracy of the winding of the path and may impair the smoothness of the winding operation This feature is not used on the last line of a subroutine hence ensuring there is no misclosure error of the payout eye position at the end of each cycle All axes positions except A return exactly to the start position at the end of each cycle If this was not the case a program with a large number of cycles would progressively shift the fibre track in relation to the mandrel in one or more axes during winding MAX SPEED AX n The user can specify a maximum feedrate for each of the axes this can be used with the speed mode options to ensure no axis goes ov
2. P38 TAPE LAY ANG P38 TAPE THICK P38 TAPE WIDTH P38 ACTION UPPER P38 ACTION LOWER P38 TAPE SPEED P38 CONE HALF ANGLE P38 START DIAMETER P38 WIND LENGTH P38 REVS BEFORE COOLING These P38 parameters are specific only the the tape edge winding parametric program and are documented elsewhere Pipe Winding Parameters see the help file section on these programs PW MANDREL RAD The mandrel radius at the start of the program PW CLEARANCE RAD The Clearance Radius for the machine PW START POS Start position from chuck datum PW WIND LENGTH Length of pipe to be wound PW WIND ANGLE 45 Cadfil Help 8 53 V7 63 For a multi layer pipe program the winds angle my be different for each layer so this parameter is best included in the start position block or the SPF header block PW WIND LAYER NO This parameter if used should be included in the start position block or the SPF header block Please note that for a pipe winding program with more than one layers the mandrel radius and other parameters changes with each layer If these parameters are used in the main MPF block the value that is used will be for the last SPF It is better to use these parameters in the start position block perhaps using the FIRST SPF ONLY if the data is not required for each layer Some parameters will probably be required for each layer su
3. T Winding T Mandrel Generate Make Template Path Reflect Path X 0 Reflect Path Y 0 Parallel Path Convert Pipe Payfile You will be asked for the name of he FIB template file For this option to work the template path MUST finish on the X 0 plane Having selected the template path the reflected path is calculated progress is indicated in the Cadfil text window The display should look as below is W ae LGA Z gt NI AL Hg 5 EE Hf Awe a E iN HNN ANAI f z ESS Ds rH 7 TI Cadfil Message My seve fibre path E As you can see because the template started on the Y 0 plane the reflection is X at the other end of the cross piece is also on the Y 0 plane Save the path you can overwrite the original template path or use a new name the latter is a better way The next step is to select the Reflect path Y 0 option from the Tee Dialog and enter the name of the path that was just saved The process is the same and at the end you will be prompted to save the new path This time overwriting the input path is OK as there was only a little work required to create it The display should look as below The next step is to create See 1 7 7 4 1 7 7 4 Tees Parallel Path In a previous section the creation of a See
4. Cancel Re calc Help 1 9 9 Visualisation of fibre Band Pattern Mandrel showing a band pattern of 3 created with the payout path viewing menus 123 Cadfil Help 8 53 V7 63 Cadfil Graphics Window stol 1 9 10 Band pattern explanation The diagram below shows a section through a mandrel showing a band pattern of 3 three starts 2 and 1 The numbers show the order in which the bands are placed on the mandrel In addition to band pattern some times the terms lagging or leading pattern may be used A leading pattern is when the bands mandrel coverage advance in the direction the mandrel is rotating a lagging pattern has the coverage advancing in the opposite direction to the mandrel rotation 124 Cadfil Help 8 53 V7 63 3 pattern 2 skips 2 pattern lagging BU 125 Cadfil Help 8 53 V7 63 1 9 11 Default Clearance Envelope 1 9 12 The Control CTL file editor Edit Modify combined winding Item Payout No of Circuits Band Mandrell Start X End X No File Layers per Lay Width File Position Position bv1 pay 57 10 00 bvi mnd 509 1 509 1 bv2 pay 57 10 00 bvi mnd 509 1 509 1 Remove Help Finish 126 Cadfil Help 8 53 V7 63 1 9 13 Dome Ended Vessel Parameters Cylinder with Endcaps Winding parameters oY Pe EA Band Width W ii p io Y pe P a 7 oa 1 U NA S a 23 W X Y Origin Pa Left End Cap Cylinder Radi
5. used in the mandrel generation these can be zero Wind Angle A This is the wind angle in degrees on the cylindrical portion of the mandre and is in the 0 90 degree rangel Because the winding is Geodesic the Clairault equation will apply hence the condition EndOpeningDiameter CylinderDiameter sine WindAngleOnCylinder Fibre Band Width W The width of the fibre band used to determine the number of cycles required to fully cover the cylinder Cylinder Clearance C1 See 1 2 1 is automatically created using this and the next two parameters This is the clearance over the cylindrical part See 1 9 13 Shaft Clearance SL amp SR 72 Cadfil Help 8 53 V7 63 Clearance on the end shafts see figure Cylinder Extension Clearance C2 The amount by which the cylindrical portion of the envelope is extended so that the winding head will clear the shoulder of the dome when it moves in at the ends see figure As can be seen in the figure the datum of the mandrel is at the centre See 1 6 13 3 must be specified in the post processor dime to relate this position to the spindle datum The user can save the data as a PAR file to retrieve latter and modify if required The user also automatically enters the See 1 4 3 to choose a band pattern End opening X and X This option is only available if the non geodesic check box is ticked This allows the end opening radii taking allowance of the band width to be different at eac
6. Degrees 70 V Mandel rotation in direction Friction Mu e g 0 2 fo2 DXF File name circle2 dxf Browse DXF Files End zone speed over ride fi 000 Boss Rotation Angle lo CALCULATE Help Hi Note that of the parameters may be greyed that is the user cannot select of enter data This is because those options are not used and are retained for compatibility with different software options or for future options Mandrel Start X Start and Mandrel Finish X These define the length X finish X start of the winding program and where it is positioned relative to the mandrel origin the x 0 position The position of mandrel origin in the machine will depend on the machine datum s and the See 1 6 13 3 described elsewhere in this help file under post processing Minimum Arc length around the section is the typical spacing of data points along the path on the mandrel surface the units will be the same as the mandrel units usually mm or inch For reasonably accurate winding about 8 points per rotation for higher angles is more than adequate however when the user looks at the Cadfil graphics the path will appear not to be smooth If good graphics are required use a small spacing Please note that calculate time will be large and the data files and winding programs will be large if the spacing is small 100 Cadfil Help 8 53 V7 63 End Plane X position amp 2 These values are used for low angles winding to limit the
7. End Zone Speed Over ride This options is not currently used The function is to apply a factor to the winding speed in the turning zone Boss Rotation Angle This option is not currently used in this option 1 7 10 6 Spar With Dome end devt The SPAR winding software is found on the QuickCAD main menu if optionally supplied This allows the winding of non round sections of constant or near constant section The section should not have concave portions as these cannot be wound successfully Click See 1 7 10 1 to return to the main topic This variant has a dome end The dome is considered to be elliptical in side or plan elevation blending from the mandrel section shape to the circular shaft The only variable describing the dome geometry is dome length which is the length from the section where the mandrel start to change shape to where it meet the shaft This length is assumed to be the same at each end of the mandrel The windows dialog below show the input parameters The winding progresses along the constant section of the mandrel at a constant wind angle the winding goes around to dome going tangent to an elliptical boss than then turns back to traverse the dime to 107 Cadfil Help 8 53 V7 63 enter the constant section of the mandrel at the correct wind angle for winding the reverse part of the circuit The control surface for the payout clearance has been extended for this option by use of the envelope vertex described be
8. IADV parameter to rather than 2 or to use a mandrel with a smaller plate height or to use a higher wind angle Setting the IADV parameter will make the most difference but then usable sample will only be obtained from one face of the mandrel WIND ANGLES ON FRONT AND REAR FACES CANNOT BE DIFFERENT FOR HOOP WINDING SET THE IADV PARAMETER IN THE CONTROL FILE TO 2 When hoop winding winding at an angle such that a full layer is produced by one carriage stroke the software demands that the ADV parameter is set to 2 The user must exit the program and change the control file to reflect this See 1 7 9 5 is discussed further in a following section 92 Cadfil Help 8 53 V7 63 HOOP WINDING 2 PAYOUT FILES WILL BE CREATED FIRST OUTWARD PATH IS xxxxxx SECOND RETURN PATH NO EXTN This is discussed in section O the user should enter a second file stem name at this prompt See 1 7 9 4 1 7 9 4 Using combining plate NC programs The plate winding program produces Numerical Control NC data which consists of a main routine which contains setup information and a sub program that describes a single carriage circuit The sub program is called a number of times by the main program to form one layer During a single carriage circuit outward and reverse strokes the carriage advances by a single bandwidth to give a progression to cover the mandrel The sub program generally contains incremental motions i e all motions a relativ
9. Mu is used to determine how quickly the fibre turns a high value makes it turn faster and visa versa A value of about 0 2 is good for most purposes If winding with pins on the mandrel near the ends use a very high value to turn the path quickly just outside the row of pins Please not Cadfil cannot defy the laws of physics wishing for a high friction value to turn a path quickly will not make the impossible possible Wind angles Degrees is the value in degrees that the user requires in the central portion of the wind path i e the total length excluding and turning zones The Low angle option does not have a turning zone as the fibre turns on the mandrel ends thus the wind angle is fully upto the mandrel end Payout clearance and mode This feature is no longer used as the clearance is always from the DXF file as this is the most general and flexible method Mandrel Direction check box If ticked default the program is generated such that the mandrel rotates in the positive direction End Zone Speed Over ride This options is not currently used The function is to apply a factor to the winding speed in the turning zone Boss Rotation Angle This option is not currently used 101 Cadfil Help 8 53 V7 63 1 7 10 4 Low Angle Parameters Flat end with pins The SPAR winding software is found on the QuickCAD main menu if optionally supplied This allows the winding of non round sections of constant or near constant section The
10. UNABLE TO READ FIBRE DATA This error is described in the section on fibre path generation errors UNABLE TO OPEN PAYOUT FILE This error can be generated in trying to read the payout path file for viewing purposes The usual reason for this will be that the file does not exist in the current directory If a new payout file is being saved the error will probably be due to an invalid name being supplied and the user can enter a new name Other possible sources of this error are listed under UNABLE TO WRITE TO MANDREL FILE heading in section 0 mandrel generation errors section ERROR READING PAYOUT FILE 115 Cadfil Help 8 53 V7 63 This message is displayed if the payout path file being read is corrupted in some way The format of the payout path file can be found in the appropriate appendix UNABLE TO READ OLD PAYOUT FILE This error is generated if a payout file that was created by a Version of CADFIL older than version 3 00 is attempted to be read for viewing After version 3 00 when the payout path viewing options were added some additional data was included in the payout path file header information This information is the payout path clearance the name of the mandrel file and the number of elements the mandrel that were used in the creating of the payout file UNABLE TO OPEN MANDREL FILE ERROR READING MANDREL FILE The payout path file and fibre path file both contain the name of the mandrel file used in their creation If
11. button to activate a new layer Enter the data specific to that layer such as winding angle etc 3 Click Add layer to add the next layer Layers can be deleted using the Delete layer button or a new layer can in inserted part way though the sequence using the Insert Layer button In both these cases the layer number in the left most column is used to select where to insert or delete a layer The date entry form allows for 10 separate layers If more are required a second pipe winding can me made using the initial mandrel radius as the final mandrel radius after the first 10 layers 4 Click the Calculate update button to fill out calculated values in the data table You will be asked to save the data and must give a file name Error messages will be given if data is incorrect or missing You must correct the data 5 After a successful Calculate update the Generate NC Data button becomes active click this to generate the complete winding program after NC generate the wind times are added to the table You get an option to view the program in the default text editor normally notepad A description of the header data is shown in the following figure 61 Cadfil Help 8 53 V7 63 Mandrel and machine clearance data Get saved data from open gt a file Eo Save new or Help modified data to a file 100 000 Cylinder Radius Clearance Radius 150
12. in the current directory If this error is caused for some other reason then contact CCL with the details If this error occurs whilst updating the mandrel in the payout path section of the software then this must be due to a system error the user should supply details of this to CCL ERROR READING THICKNESS FILE This error is caused due to an error in the format of the thickness file The format and structure of this file can be found in the appropriate appendix If this error occurs whilst updating the mandrel in the payout path section of the software then this must be due to a system error and the user should supply details of this to CCL 1 8 6 Fibre path generation errors UNABLE TO READ FRICTION VALUE This message indicates that there was an error reading the friction value from the materials file or that the materials file was not found The name of the materials file is MATERIAL CNF If this error message occurs then a friction value of 0 124 is assumed See 1 10 2 3 can also be found in the Appendices UNABLE TO WRITE TO FIBRE FILE 112 Cadfil Help 8 53 V7 63 This message indicates there was an error writing the fibre data to disk This could be for a number of reasons which are listed in the previous section under the heading UNABLE TO WRITE MANDREL FILE This message indicates that the fibre path has not been successfully saved FIBRE DATA NOT WRITTEN This message occurs when saving the fibre path if the fibre
13. jam 9 aes eer T a as Ofer E LELUT IE Total Wind Time EEEH 60 Cadfil Help 8 53 V7 63 Pipe Winder Overview The Cadfil Pipe winding software is designed for higher angle winding 40 90 degrees on pipes and is ideal for use on 2 axis winders When Pipe Winder is included as part of a higher specification package e g Cadfil Lite then more machine axes may be available Multi layer and angle winding patterns can be quickly generated with both hoop 90 degree and helical winding Pipe winding is not suitable for low angles less than 30 degrees as this involves winding over an end cap For such applications Cadfil Lite is more suitable The thickness of the winding and winding times are automatically calculated Each layer is calculated making allowance for the thickness of the previous winding to ensure band pattern and fibre angles are always optimum For each later the turning length at the end where with winding angle is changing for the turning around is automatically calculated For some applications this length is considered as waste as it is cut away after winding Creating a program with pipe winder is simple There is a single window dialog box data entry screen show on the first page of this document The steps for program generation are 1 Enter the Header Information Basic information such as mandrel diameter and the fibre band width that is constant for each layer 2 Click The Add layer
14. the See 1 6 1 with the following exceptions i Only the mandrel rotation and carriage machine axes are used ii The user is required to enter an additional clearance parameter iii There are limitations on the winding of low angles The 2 axis post processor where supplied can be executed by selection at the appropriate post processor menu option The system is intended primarily for use with a payout eye The eye travels along a line parallel to the machine X axis in the Z 0 plane After the entry of the Payout extension the user is requested to enter a payout clearance with the prompt ENTER PAYOUT CLEARANCE FOR 2 AXIS SYSTEM xxxxxx The value in the square brackets is the default value and can be accepted by hitting OK with no other input Another value can be entered if required This clearance must be supplied in the mandrel units and is added to the maximum mandrel radius for the particular mandrel used This then fixes the distance from the winding axis of the line the payout eye moves on Because there is no cross feed travel if the winding program has low zero is axial winding angles then the machine carriage travel to achieve the desired position will be large This may be greater than the machine travel available or may give poor fibre control due the large distance between the payout eye and the contact point on the 47 Cadfil Help 8 53 V7 63 mandrel The end overshoot effect can be reduced by d
15. the spacing is small 103 Cadfil Help 8 53 V7 63 Dome length Not used in this option as there is no dome Set to zero End Plane X position amp 2 These values are used for low angles winding to limit the travel of the mandrel carriage at the mandrel ends and to determine the smallest radial position the cross feed axis can move in to at the mandrel ends Position one is at the X end of the mandrel and position 2 is at the X end If these items are greyed they are not required for the winding option chosen WARNING the machine can move inwards and could clash with the mandrel if the planes are not positioned outside the extremes of the constant spar section Dwell Hold radius The machine will move do this distance from the winding axis on the end planes whilst the fibre is wrapped around the mandrel shaft Bandwidth is the actual width of the fibre band to be used This is used to calculate the number of carriage circuits required for a layer and is also used for the graphics of the banding structure End turning length is the distance at both ends of the mandrel than can be used to turn the fibre The fibre starts at hoop and progresses down to the required winding angle If the software can achieve the required wind angle in a shorter distance it will do so and the length of winding at the required angle will be correspondingly longer If the length is less than that actually required a warning is given and the wind angle that is
16. travel of the mandrel carriage at the mandrel ends and to determine the smallest radial position the cross feed axis can move in to at the mandrel ends Position one is at the X end of the mandrel and position 2 is at the X end If these items are greyed they are not required for the winding option chosen WARNING the machine can move inwards and could clash with the mandrel if the planes are not positioned outside the extremes of the constant spar section Extra Dwell 1 amp 2 is a distance circumferentially around the mandrel at either end that the winding will dwell This is a minimum value as additional dwell my be required for the purposes of making a proper winding pattern Bandwidth is the actual width of the fibre band to be used This is used to calculate the number of carriage circuits required for a layer and is also used for the graphics of the banding structure End turning length is the distance at both ends of the mandrel than can be used to turn the fibre The fibre starts at hoop and progresses down to the required winding angle If the software can achieve the required wind angle in a shorter distance it will do so and the length of winding at the required angle will be correspondingly longer If the length is less than that actually required a warning is given and the wind angle that is achieved will not be the specified wind angle the wind angle that is achieved is reported to the Cadfil text window Friction coefficient
17. 1 3 6 Creating a fibre pathiewec cacasiins wisn ersieindihiiie a a aea 19 1 3 7 Specific Wind angle TEQUInE oil eoese coeds posngasars eaenatedonaccsnatacodigemanobanneaneniaoaaeies 20 1 3 8 Specific diameter opening TEQUITEM ses csswranv sees ecpyncuenwesencypucrawcdneneocewucs 21 F 3 9 Diffic lt Tam Te Spa isie e bocce oe cea a seve test ar a ar Tea aT EEEE ERE ges 22 1 3 10 The fibre path creation menu ssssseessseeessersseresssesseesssetsseressresseesseessseessees 22 1 3 11 Fibre Paths Display Options wis wssisetncsisicein niente snide 24 1 3 12 Friction amp Step DIB OS a c Gis cas ada haces oss o irah ape REETA eee a 25 13 13 Views Men ne i ee eC ee eS Se Oe eT eee eae aE T 26 1 3 14 Creating a Joining Path secs case cniuses vaecensrosshetviencswiirenawmaviesaieueciens oeieeeicoess 28 TA Payout Path Crea ion 25525 cgenceriudetag a e a A E A aeons 29 1 4 1 Introduction to payout path creation eesseessesessesesessersersresrersrrsresrersresreseesers 29 1 4 2 Creation of payout path sssssesesesesssesseeessersseressressresseeessereseresseessereseeessees 30 1 4 3 Band pattern SECC TION insinsero n v 31 1 4 4 Band Pattern With Dwell Winding 00 eee eeeeceeeneceeseeeeeseeeeeneeeeeeeeeeeeeees 33 1 4 5 Filter length and filter angle ed esata ant tacit eas ace ete sccadaches soad oie dates set vay 34 1 4 6 Thickness modificaion Snin othde cars aud e a A thal acy stebanel Bade 34 LAL View payout pathes oreren een Goesuedeeteg
18. 2 122562E 04 624436E 02 988438E 02 952736E 01 3 122538E 04 632031E 02 104283E 03 952736E 01 4 122445E 04 660813E 02 110899E 03 783398E 01 138 Cadfil Help 8 53 V7 63 5 122328E 04 697469E 02 118565E 03 553718E 01 6 122241E 04 724843E 02 121806E 03 483378E 01 7 122000E 04 800000E 02 127532E 03 378905E 01 The data contained within the file has the structure as outline below Number of lines of data in file Mandrel name used in fibre generation NOCYCLXSECARBANDW COLUMN HEADER INFORMATION POINTXCOORDRADIUSANGLETHICKNESS Where Format NOCYCLNo of Cycles required for coverage Free XSECARTow bundle cross section mandrel units Free BANDWIDTHBandwidth used in Payout Path Generation Free HEADERColumn Header Information for data below POINTReference number of line in data file 16 XCOORDX co ordinate of point Mandrel Units E13 6 RADIUSRadius of mandrel at point E13 6 ANGLEAngle of fibre in degrees at X Co ordinate E13 6 THICKNESSThickness of laminate at the X Co ordinate E13 6 1 10 3 Appendix B Calculations 1 10 3 1 Useful Calculations On the utilities menu there is an option to make some calculations using equations useful in filament winding amp composites The user enters the data in the boxes for the calculation required and then clicks the Calculate button to put the answer in the results box The calculations currently available are 139 Cadfil Help 8 53 V7 63 Calculate the
19. 3 13 This allows the view angle to be changed output of graphics and other facilities such as ZOOM and PAN This is described in a later section of this manual This dialog also allows the user to change how the See 1 3 11 Rotate about Axis This option enables the user to rotate the fibre path around the mandrels axis of revolution in the current view Whenever a new view is selected any relative X rotation entered using this command is lost as the display is mandrel and fibre are drawn in the selected view orientation The system prompts Enter relative x axis rotation a value in degrees should be entered The fibre path will then be redrawn the original path remaining visible The value entered here is the motion to move the fibre track from where it is now to its new position The can help if the fibre is on the back face of the mandrel Redraw This clears the screen and draws the fibre and mandrel mesh in the currently selected view with the current display options PATRAN Output This option allows model data to be output as a PATRAN neutral file containing shell elements The user is asked for the name of the file to create The 23 Cadfil Help 8 53 V7 63 extension ptn is added to the file name entered This option may not be present as this feature is an additional software licence item Test Hoop Points This prints a summary to the text window of the X position and radial opening for each hoop point in the winding fil
20. 4 POS AX 4 XDAT GEARING AX 4 AX STATUS 4 SP_AX_5 OFFSET AX 5 POS AX 5 POELEN GEARING AX 5 AX STATUS 5 57 Cadfil Help 8 53 V7 63 SP_AX_6 OFFSET AX 6 POS AX 6 GEARING AX 6 AX STATUS 6 For the Rotary axes Mandrel eye roll eye yaw SP_AX_1 OFFSET AX 1 POS AX 1 GEARING AX 1 AX STATUS 1 SP_AX_2 OFFSET AX 2 POS AX 2 GEARING AX 2 AX STATUS 2 SP_AX_3 OFFSET AX 3 POS AX 3 GEARING AX 3 AX STATUS 3 Where SP_AX_nis the computed absolute start position off the winding machine for axis n OFFSET AX nlIs the machine constant from the reference home position of the machine to the spindle datum for axis n See 1 6 2 _ GEARING AX nlIs the relation between mandrel units and machine units See 1 6 2 AX STATUS ntakes the value 1 0 or 1 depandant on the postive direction of axis the machine with respect to sign convention used in CADFIL for axis n zero indicates the axis does not exist on the winding machine XDAT and POELEN are values that are usually requested each time a file is post processed If the Payout eye the fibre dispening tool is never changed on the machine then the offsets can be set up so the POELEN is always zero XDATis to position the mandrel in the machine It is from the spindle datum to the mandre datum origin It is in mandrel units POELEN Is the length of the payout eye roller comb etc it is in the mandrel units POS AX nis the start positi
21. 63 be given a particular width and the effects of band twist can be observed If this option or Animate Dynamic is selected the user will be asked to specify the post process type so that the animation can show the machine motions for different post process options Post process options are discussed in a later section of this manual Animate DynamicThis is similar to Animate Static The head is successively draw and then removed as the payout program is stepped through This takes the form of an animation to visually see the head moving around the mandrel Pick Display PointsThe system goes into the Animate Static mode but the user is asked to enter the point number s of a particular payout position s The user may have identified a particular point s of interest perhaps for graphics output Using this option the user can display the payout head for the chosen position The mandrel and head are drawn using the current view options e g SHADE mode VIEW and ZOOM scale Element SelectOnly used for RTM Non axisymmetric work Node SelectOnly used for RTM Non axisymmetric work FLE OutputOnly used for RTM work CFILL OutputOnly used for RTM work Boundary PlotOnly used for RTM Non axisymmetric work CFILL ResultsOnly used for RTM work EXITThis option returns control to the previous menu 1 5 Combining Winding Programs 1 5 1 Control File for creating multi layer wind paths A control file can be created in the Combine Programs on the NC Pos
22. A summary can be found in the text window see below C Users Andrew Desktop arco09 t4c fib t4c fib Reading file gt Reading cadfil fe format data Creating payout path length filter 3 24 mo filter points is 609 lift of points removed is 50 lift of points removed is 50 lift of points removed is 8 lift of points removed is 8 lift of points removed is o lift of points removed is o Total excluded points is 667 C Users Andrew Desktop arco09 fred pay fred pay Payout files s created Reading cadfil fe format data fal 85 Cadfil Help 8 53 V7 63 The final step is to give the payout path a file name The default is the same name as the FIB file but with the PAY extenstion The payout path is created using the See 1 7 7 1 specified when the mandrel was generated The final step is to post process the path The 4 axis no twist option or the 6 axis options should be used 1 7 8 Sphere Winding 1 7 8 1 Sphere parametrics Show Picture The sphere parametric automatically creates multiple winding programs for providing a mufti angle layup on spherical components The programs give near uniform thickness distribution particularly if the filament bands are thin and a large number of layers are used Because multiple wind angles are used the resulting composite is effectively in plane quasi isotropic and this gives maximum efficiency for a spherical pressure vessel Ultra high performance pressure vessels have
23. CADFIL the user can create a custom machine envelope In this section the user gives data relating to the materials that he will be using during the winding of the component From these data the system calculates the fibre bundle cross sectional area and by inclusion of the bandwidth will enable the system to calculate the thickness of the composite to be laid down and the minimum number of cycles for complete coverage 29 Cadfil Help 8 53 V7 63 A feature now exists which plots the payout eye path along with the mandrel This enables the user to view the payout eye motion in relation to the mandrel Viewing options enable user to view the mandrel and payout path from any direction whilst also permitting the operator to rotate the payout eye path around the mandrel The user can also view the band structure of the winding using the See 1 9 9 option The software has the ability to update the mandrel profile This option enables the user to modify the profile of the mandrel used to generate the fibre path by adding to it the thickness profile of the layer to be over wound This will enable the user to generate subsequent fibre paths onto the modified profile See 1 4 2 1 4 2 Creation of payout path At the CADFIL main menu select the Create Payout Path option The system will request the name of the fibre path FIB file to use The system reads the fibre path data and then reads the mandrel and envelope file data that is refe
24. ELEMENT ASPECT RATIO WARNING IN FIBLAY PATCH ASPECT RATIO OF 10 1 HAS BEEN EXCEEDED THIS MAY RESULT IN INACCURACIES IN THE PATH GENERATION THE DIAGNOSTIC OUTPUT BELOW IS GIVEN AS GUIDANCE TO MANDREL MODIFICATION IF THIS IS REQUIRED NUMBER OF ELEMENTS 34 MANDREL STATIONS PATCH SECT1 SECT2 RADIUS LENGTH WIDTH RATIO 1 2 101 500 203 171 18 730 10 8471 2 3 101 500 112 000 18 730 5 9796 2 3 101 500 112 000 18 730 5 9796 3 4 101 500 17 763 18 730 9484 3 4 100 000 17 763 18 454 9626 9 10 50 800 17 761 9 374 1 8946 9 10 34 700 17 761 6 403 2 7737 10 11 34 700 17 611 6 403 2 7503 10 11 17 700 17 611 3 266 5 3918 11 12 17 700 17 763 3 266 5 4384 END OF ASPECT RATIO CHECKING ERROR POINT ON MANDREL SECTION This error occurs when specifying the start X position for the fibre path when this position corresponds exactly with the X position of a mandrel section Starting exactly on a mandrel section causes a numerical problem and hence is not allowed The user is 114 Cadfil Help 8 53 V7 63 forced to re enter the start position If required this can be a very small distance from the original position selected FIBRE AT MANDREL END This message is displayed when the fibre reaches the end of the mandrel without turning around After clearing the message the user can deal with this problem in a number of ways It may be possible to delete a few fibre steps and then to apply friction such that the f
25. End 2 B Envelope from DXF Dwell Hold radius Payout Clearance Band Width 200 End Turing Length Wind Angle Degrees J Mandel rotation in direction Friction Mu e g 0 2 DXF File name circle2 def Browse DXF Files End zone speed over ride i 000 Boss Rotation Angle fo There are five button options CANCEL to quit without saving HELP to jump into this help file READ PARAMS to read a set of data parameters created at an earlier time and that were saved to a PAR data file WRITE PARAMS to write the current data parameters on the screen to a PAR data file See 1 7 10 2 to select from existing DXF files and add the DXF name to the winding data parameters The DXF file contains the mandrel section and clearance geometry Rules for creating this geometry are given by See 1 7 10 2 97 Cadfil Help 8 53 V7 63 CALCULATE to save the existing winding parameters on the screen and if possible calculate the winding pattern using them some useful information messages are given to the Cadfil text window read them 1 7 10 2 DXF file for Spar winding The mandrel is generated from a cross section created in a external CAD program such as AutoCAD The section is supplied in the form of a DXF file To allow Cadfil to successfully use the DXF file some rules MUST be followed a The Mandrel data is defined by a 2D profile in the X Y plane using lines and circular arcs Please note that circular arcs that are greater
26. Fibre Fraction By Mass from the fibre fraction by volume Calculate the Fibre Fraction By Volume from the fibre fraction by Mass For an axisymmetric body calculate the geodesic fibre angle at a given mandrel diameter given the angle and diameter of another known point on the path This uses the Clairault equation For an axisymmetric body calculate the geodesic fibre diameter position for a particular wind angle given the angle and diameter of another known point on the path This uses the Clairault equation We can add other calculations if required If there is an item you would like adding here then please Contact us Details can be found in the Introduction to this help file 1 10 3 2 Tow area calculation sean TE et K P FMR p Area Area of tow bundle Tex Total Tex of fibres in bundle e g 2 fibres of 2400 Tex 4800 pe Resin Density Pr Fibre Density K Area calculation constant FMR Mass fraction of fibres in composite For the Area calculated to be in correct units the formula is required to produce an area in the same units as the mandrel was initially generated in Thus the units of TEX Fraction Mass Ratio etc need to be consistent Example Densities Grams Per Cubic Centimetre TEX Grams Per Kilometre K 1 10 3 3 Mass fraction from volume fraction P FVR EMR t 0 FVR p l FVR 140 Cadfil Help 8 53 V7 63 Resin Density Dr Fibre Density Df Mass fraction of fibres in c
27. NE PR Cer Ente oe A A ere ere 59 1 7 1 QuickCAD Parametrics Introduction cccccccccssssssseceeccceeeseesssnseeeseeeees 59 L2 PI PS Windin Seisean eir aoe aE EE OE OEE EEA OEE ETERS 60 1 7 3 Cylinder Hoop WIA g iiieoo iie 68 1 7 4 Dome Ended Vessel Parametric noosssesssseeseresseesseesseersseressrersressereseeessens 71 1 7 5 Vessel With Encaps Beta Version sessssesesssesssessessseeesseressresseessereseressere 73 1 7 6 Elbow Winding erno extvcdudes denoudenucbiav ie a e E E TNES 74 177 Tee Windin seen n A e AEAEE TIER 77 DFO Sphere VV MINGLED etei a ta epson von R E uemeat ayia 86 177 9 Plat Plate Winding yc secccssstiaiestasyencsvacaversconcenaedeaeniseassecaeenseunnvplanaeasesnieeeds 88 I ALOSPAR Windings icirem a a i a casemate aban ates 95 ESError Messag S nena a e a a a e aa aE 110 1 8 1 Introduction to error handling sssessseseessseeesseesssreseresseesssersseressresseesseeesee 110 128 2 Fatal error S ess osese a RS re SaN RE ATREA cant E STESA E 110 1 8 3 N n fatal rrr aiena E a RE E evden ene ae 110 1 8 4 Cadfil main program errors Messages sssessesesssesseesseesssetssereseresseesseeesee 111 1 8 5 Mandrel generation error messages sssesseeessresssesseessertssereseresseesseessee 111 1 8 6 Fibre path generation errors siccseevcsisentecenasieetecaseesesneecoesistagveosevsduisedecerweries 112 1 8 7 Payout path error messages esesssesseseeseseresrersessresrersrestesrrsstesresers
28. Note that the bands close up to the shaft as we selected an opening radius that matched the shaft radius If the X end is viewed you can see the difference in the end opening sizes as shown below There are many other view options you can look at when finished click exit and then select Finish from the Payout View Menu 146 Cadfil Help 8 53 V7 63 The last stage is to create the NC data From the NC Post process menu select 4 axis post process and after a couple of click you have the program data to view on the screen Note that questions asked during post process are customer specific and items can be de configured in not required if the items in question are not available or always standard settings on your machine To wind this program you must have a valid post processor configuration with the correct reference point data for the winding machine 2 Addenda 2 1 USB Datakey DK3 2 2 Difficult mandrels With certain mandrels it may prove difficult to achieve the desired fibre path Mandrels having concave sections can cause problems as it may be found that the fibre turns around in the concave section of the component See 1 3 9 in order to avoid difficulties due to turn around or lift off within this section it is recommended that the user start the fibre at the minimum radius within this section and travelling in a near hoop direction The path is developed around the mandrel until the See
29. REOTA E Ea RT E ANTE A KR eaei 36 1 5 Combining Winding ProgramSs eesesseessesesseesseressressressrrssseessersssressresseeesseessere 37 1 5 1 Control File for creating multi layer wind paths ssssseesseeesesesseessersseeesseee 37 TO OSU PROCESS meenen a E E ESE 38 1 6 1 Introduction to Post Processing eesesesesseresseesseesseessetsserssseesseesseeesseessens 38 1 6 2 Post processor configuration SM File ssesssesseessessseersssrssseesseesseesssressens 39 1 6 3 Post Processor Configuration LOGICALS 00 eeceeeteeeeteeees 43 1 6 AS Thie 2 axis Post Processor vernie idii deel i i 47 1 6 5 The 3 and 4 axis POSt ProceSSOMS esscceessceceseceeeseeeeseeeesseeceeeeeesneeeeeteeeees 48 1 6 6 The 3 axis large eye post ProcessOr siiescsssshe sank scuesdiagstaaiedeeheeaeagendeageetennioaee 48 1 6 7 The Sakis postprocessor Basu se cagess steel e a a A a ees 48 1 6 8 The 5 axis post procrocessor 2 s ssesesesesseressresseesseessstssrrsssresseessereseessers 49 Cadfil Help 8 53 V7 63 1 6 9 The 5 axis 3 plane post ProcessOM say stages sitnawiatea heashedpen hacer oavn belts 49 1 6 10 The 6 axis post processor Mvs soniinsisicedaess ses gss apes dees dos gsc toodscacevponsadeeateeeeeegeaes 49 16 10 Whe G axis post PrOCESSOM 2 ssnstinin asane eaae an e Aa 50 1 6 12 Transfer NC t Winder ssccoiiecinicennc iinei anaes 50 1 6 13 Post Processor Put nonesis a e eaii 51 T7 OuickGCad kre tee renner A Ment Opa yen
30. XR Record Edit x R Extra Points Fit Radius 503 090 95 106 0 0 000 1 9 4 Axisymmetric path Requirements 2 Hoop Points Cadfil Graphics Window Ee Ea 1 9 5 Winding Angle System For Starting Path Zero degrees is along the mandrel axis in the X direction left to right as normally viewed on the screen 180 degrees is along the mandrel in the X direction Negative wind angles will lead to the path spiralling around the mandrel on the opposite sense and will lead to negative mandrel rotation during winding 120 Cadfil Help 8 53 V7 63 135 45 K 0 degrees 135 n 1 9 6 Friction Direction looking on to mandrel surface Right Hand Friction 121 Cadfil Help 8 53 V7 63 1 9 7 Difficult Mandrels z a n a z g 5 a O Start in Concave area at a high angle eg 85 122 Cadfil Help 8 53 V7 63 1 9 8 Band Pattern Selection Dialogue Band Pattern Selection Number of cycles 30 to 30 Initial Rotation 11 Revs s 15 3612 Degrees BAND NO OF TARGET PATTERN CYCLES REVS ANGLE CHANGE FACTOR 84 00 1 0173 0 0173 132 00 1 0283 0 0293 156 00 1 0354 0 0354 204 00 1 0475 0 0475 228 00 1 0535 0 0535 276 00 1 0656 0 0656 348 00 1 0837 0 0837 12 00 1 0897 0 0897 oa ada oe why P Click on pattern then Diyeli s0 0 56 0 OK or i _ Set new cycle range and C Prowression SEER SDIT Bene te click Re calculate Cancel sets no pattern Extra dwell deg
31. a payout path file or fibre path file is being read the mandrel file also needs to be read The nature of the errors is the same as those described in the mandrel generation section The likely causes are that the mandrel file has been deleted or that the payout fibre file has been copied to a new directory but the mandrel file has not It error could be caused by a user editing the payout fibre file and modifying the name of the mandrel file that is contained in it PAYOUT PATH DATA NOT WRITTEN This message can be produced when the user is trying to create a payout path file when the file already exists and the choice not to overwrite this existing file has been made After clearing the message the user is requested for a new payout path file name to use ERROR WRITING TO PAYOUT FILE This error indicates that the payout file has been successfully opened but that there has been an error writing data to it This is most likely to be due to the disk being full If this is not the source of error then there has been an unexpected error and the user should contact CCL with the details FIRST HOOP POINT IS TOO CLOSE TO START OF PATH RE CREATE FIBRE PATH STARTING AT HOOP As explained elsewhere Cadfil requires two hoop points in the fibre path to be able to create a repeatable cycle Hoop points are created in two ways The first method is when the fibre is started exactly at hoop and the second method it were the fibre is developed until it turns
32. achieved will not be the specified wind angle the wind angle that is achieved is reported to the Cadfil text window Friction coefficient Mu is used to determine how quickly the fibre turns a high value makes it turn faster and visa versa A value of about 0 2 is good for most purposes If winding with pins on the mandrel near the ends use a very high value to turn the path quickly just outside the row of pins Please not Cadfil cannot defy the laws of physics wishing for a high friction value to turn a path quickly will not make the impossible possible Wind angles Degrees is the value in degrees that the user requires in the central portion of the wind path i e the total length excluding and turning zones The Low angle option does not have a turning zone as the fibre turns on the mandrel ends thus the wind angle is fully upto the mandrel end Payout clearance and mode This feature is no longer used as the clearance is always from the DXF file as this is the most general and flexible method Mandrel Direction check box If ticked default the program is generated such that the mandrel rotates in the positive direction End Zone Speed Over ride This options is not currently used The function is to apply a factor to the winding speed in the turning zone Boss Rotation Angle This option is not currently used in this option 104 Cadfil Help 8 53 V7 63 1 7 10 5 Spar With Dome End The SPAR winding software is found on th
33. and cannot be used A security error message may be given and you could be directed to this help file if you chose to be To fix this you need to go to the utilities menu and select the Apply New Licence file option You will then need to browse in the file open box to find the licence file you saved earlier Having read the licence file you can then see the Cadfil the Message Licence Update Succesful in the Cadfil Text window you may need to scroll down this window to read the messages If you get an error please note the error number and contact CCL It may be that you need an updated licence file Security error messages will be of the format Security failure code xxx View Help Error codes meanings are shown below It is suggested that you a Check the Datakey is plugged into the PC and try to run Cadfil again After plugging in a key wait a few seconds for windows to find it b Re install the driver files see step 2 and try again c Contact CCL For other codes you may just need to apply the latest licence file as described above If the error persists please contact CCL Contact details are at the start of this help file and can also be found on the Cadfil About option Cadfil Run Time Licence code errors 1 No DK3 driver 2 No DK3 found 5 16 17 Corrupt DK3 datakey data 6 7 8 18 Licence expired 9 DK3 found but not recognised not initialised by Cadfil 10 11 13 14 15 Only for DK12 p
34. and controller used and to be familiar with these It is also advisable to keep a record of all user program numbers as they are used See 1 6 13 8 1 6 13 8 Calculation and output of NC part program After the data input is complete the post processor then proceeds to process the payout data and create a program file A message is displayed to the screen when all the data has been processed The initial post processor menu is re displayed to allow the user to process further data or to exit Various error messages are displayed if problems occur These should usually be self explanatory otherwise see the errors section 1 6 13 9 Calculation of program start position If the reference point data given in the machine data file SM is correct and if the XDAT and payout extension values POELEN specified by the user are also correct then the automatic start point will be correct If any of the above data is incorrect the command for the motion to move to the program start position is useless The possibility of the payout arm crashing with the mandrel exists if the program is used to move to the start position as intended This section shows how the start point is calculated from the data supplied to the program It is intended as an aid so that the user can check if he wishes to Follow the link to view a diagram for Offsets XDAT and POELEN See 1 9 20 For the Linear axes carriage cross feed and Vertical SP_AX_4 OFFSET AX
35. at a later time When you are happy with the data click the Calculate button The fibre path and payout path are calculated you select the pattern from the pattern table If you want to know more about the pattern table click on the help button For this example we select option 1 is a 4 start band pattern You will then automatically enter the payout viewing options From the Payout View Menw select View Options Then Select from the Select What to Display pull down box and pick option 10 Mandrel Fibre Bands as shown in the picture to the below Then click Draw 144 Cadfil Help 8 53 V7 63 View Zoom Graphics Select hatto peau Mandrel amp Fibre Line Mandrel Fibre Line Payout Marks Mandrel Payout Path Payout Marks Fibre Path Payout Path Marks 2D Payout Marks Fibre to Payout Point Lines Animate Static All Animate Dynamic Animate Static Pick 10 Mandrel Fibre Bands M Show Patch Edges Shading off Soyo wh a I Invert Zbutfer C Linear Shading d M Back Surface Cull C Shading Bilinear Zoom Pan Options Zoom Window Pan View Step Options l Draw Path In Steps Zoom All amp Step Size plane Zoom Factor fe ZoomFector Xplane2 Select the View angle pull down box and pick the X end option and then click Draw to draw this view the result should be as shown below 145 Cadfil Help 8 53 V7 63 KA
36. datum point to the mandrel origin The Units of XDAT must be those used to define the mandrel See See 1 6 13 9 for additional information 1 6 13 4 Entering the Payout Eye Length POLEN The user is prompted ENTER POE EXTENSION in a dialog The payout eye length POELEN is the length of the tooling that dispense the fibres on many machines this is an interchangeable component See 1 9 20 This default value can be accepted or a new value can be entered for the specific payout eye to be used A default length can be specified in the SM See 1 6 2 using the variable PA YOUT EYE DEFAULT LEN 75 in this case setting the default to 75mm If no value is set the default is zero Note that there is a variable ASK FOR PA YOUT EYE LEN that can be set in the machine configuration SM file If ASK FOR PA YOUT EYE LEN 0 then the user is not asked for the POELEN value and the default value it is assumed The default is to ask ASK FOR PA YOUT EYE LEN See 1 6 13 5 52 Cadfil Help 8 53 V7 63 1 6 13 5 Selection feed rate calculation method The See 1 9 17 allows the user to set the winding speeds and method to use to calculate machine feed rates The Feed rate dialog now shows the maximum speeds feed rates for each axis and also the maximum accelerations for each axis If an axis exceeds the maximum set speed in a particular line of motion the overall feed rate will be reduced The accelerations are only used if the acc
37. down on the mandrel if you consider it as a tape One way to measure is make a single layer of hoop and the band thickness is half the increase in mandrel diameter Start position This is the position along the machine carriage where the winding will start It is measured from a fixed position often the machine chuck face or headstock This reference is set up in the post processor configuration file Your machine supplier or software supplier should be able to advice or set up this file The total length of winding is exactly what it says This included any turning length so if you need a length of tube with an exact wind angle all the way along it you will need to use a longer wind length to allow for the turning length The waste is automatically calculated So if you want say 2000mm at 45 degrees enter this data and calculate If the waste length is given as 200mm then increase the total length of winding to 2200mm If a negative length is used the winding will start in the negative direction of 62 Cadfil Help 8 53 V7 63 the carriage so the start position must be specified to suit this there is a diagram latter in this document The friction coefficient is used to calculate the turning area Cadfil supplies a default value but this can be changed by the user If friction is increased the tuning lengths get shorter but if too high a value is used the fibres will slip Typically a value of 0 1 0 2 is used Mandrel rotation 1 1
38. factor of 25 4 and all the values will multiplied by this factor and thus converted The mandrel should then be saved with the updated data The scale factor is not saved or retained in any way Cadfil does not know the actual units used for the mandrel these are just dimensionless units If the units used for the mandrel do not match the linear units for the winding machine then conversion gearing factors must be specified in the post processor configuration 1 2 3 Importing a DXF file On the Cadfil Utilities menu there is an Imported DXF option This reads a DXF file created in a CAD program and creates a mandrel file For this to work the DXF file must be prepared in a certain way as described below The Mandrel data is defined by a 2D profile in the X Y plane using lines and circular arcs The axis of the mandrel should be the World X axis The Lines and arcs for the mandrel must be joined to form a polyline or lwpolyline This polyline must be on a layer called MAN The layer called MAN should contain only one polyline but can contain other data The Envelope data optional must be prepared in the same way as the mandrel contour The envelope polyline must be on a layer called ENV In the CadfilXXX Data folder there is a sample DXF file called TESTMAN DXF Cadfil has been tested on AutoCAD R12 R13 R14 amp 2000 DXF files 15 Cadfil Help 8 53 V7 63 1 2 4 Converting Old mandrel files At version 5 the format of the Cadfil man
39. file already exists in the working directory and the user has chosen not to overwrite this data This user should select the option to save the data again and enter a new file name or decide to overwrite the existing file WARNING LESS THAN 16 ELEMENTS This message is displayed if the user enters a value of less than 16 when requested for the number of elements for the surface mesh A value of 3 or less is not allowed and the user is forced to enter a new value The values 4 to 16 can be used but the user is asked to exercise some caution as the surface mesh is poor and hence this could lead in inaccuracies in fibre generation In this case the user can keep the value chosen or can elect to enter a new value TOO MANY ELEMENTS For speed of computation certain parts of the surface mesh are contained in the computers memory Because the memory of the computer has limits there are limits to the size of the surface mesh that is possible This message occurs when the number of elements chosen for a particular mandrel will lead to there being too much mesh data to fit in the computers memory The user is forced to enter a new value after the error message has been cleared The maximum number of elements that can be specified is a function of the number of sections on the mandrel and hence more elements can be used where there are less mandrel sections For most purposes a number of elements of around 30 is acceptable WARNING ELEMENT ASPECT RATIO E
40. frequently encountered in path development Due to the wide variation in mandrel design and operator path requirements this manual cannot however be expected to cover all possible permutations that could be achieved The examples have therefore been chosen to enable the user to quickly gain an appreciation of the capabilities of the software whilst providing the knowledge of how to develop fibre paths for the majority of applications See 1 3 2 1 3 2 Mandrel Meshing for fibre path generation In order to avoid potential problems during fibre path generation it is advisable that the user attempt to maintain the aspect ratio of all elements to be as near to a ratio of 1 1 as possible In practice this is difficult and a wide variation in the aspect ratio of elements is to be expected However we do recommend that elements do not exceed a ratio of 10 1 in any direction and that a minimum of 16 elements per revolution be used Larger aspect ratios may lead to inaccuracies in path generation though this is not necessarily the case A warning is given for elements that exceed the advised 10 1 ratio the elements concerned are listed to the errors logging file CADFIL LOG 16 Cadfil Help 8 53 V7 63 The main reason for such an error to occur is where cylinders have been defined using a few points giving rise to large X co ordinate steps This can be rectified by inserting additional points where necessary in the mandrel data file in the
41. generation and will enable fibres to be laid at the precision of the filament winding machine used rather than with the inaccuracy of the teach In method The system determines geodesic or frictionally modified geodesic fibre paths on the surface of an axisymmetric mandrel These paths are subsequently processed into machine independent co ordinates Finally this data is translated into the numerical code for the defined winding machine controller This is subsequently transferred to the Cadfil Help 8 53 V7 63 winding machine controller The system can be configured to generate programs for a wide variety of machines CADFIL assumes that the user is a competent design engineer with knowledge of composite materials It will enable such a person to establish the required laminate structure on a mandrel and create a NC program for the target filament winding machine CADFIL is menu driven and operates on a PC using the the Windows operating systems The current level is designed and tested for Windows XP Vista and Windows 7 1 1 3 Installation To install Cadfil the installer must have administrator rights on the PC for steps 1 2 and 4 STEP 1 Install Cadfil Cadfil comes as an executable install file When run the install file e Copies files to the C CadfiNcadfil7xx folder 7xx is the version number e g 7 01 would be 701 e Creates Registry keys e Creates shortcuts on the Start menu in the programs area e Creates a D
42. i e 7 9 11 The programmed fibre path on the mandrel surface assumes that the end of the edges of the plate are round with a radius equal to half the plate thickness This results in a smoother machine motion when winding and reduces snatching of the fibre that could cause fibre breakage It is not important for the mandrel to actually have rounded edges but some radius is recommended on the plate edges as a sharp corner can cut the fibres All the data points on the winding paths are on the rounded ends the path across the plate is always a straight line This parameter is the number of data points in the fibre and payout track around the mandrel edge There will be 2 NPT data points per mandrel rotation when winding For accuracy the software does not allow a value for NPT of less than 7 if a value of less than 7 is used the software will warn the 89 Cadfil Help 8 53 V7 63 user with a message and then actually use a value of 7 If an even value of NPT is used the software will warn the user and will use a value that is 1 greater Advance Parameter IADV The is an integer value and takes the values 1 or 2 If one is used the required wind angle is only given on one face of the mandrel The other face will have a wind angle of around 90 If a value of 2 is used See 1 9 15 the wind angle is given on both faces but the length of mandrel required for a specified sample length will be much longer Mandrel length is an issue
43. if the mandrel is to be rotated about both axes as the length cannot exceed the maximum machine capacity for diameter For wind angles that are less than about 60 slippage at the plate ends may occur when the wind angle is on one face only See 1 9 16 and therefore the wind angle must be specified for both mandrel faces in this case TADV 2 Wind angle THETA The wind angle specified is always the angle relative to the machine carriage axis For example 90 is hoop fibres and 0 is axial fibres with respect to the machine carriage axis The advance parameter above can be set to give this wind angle on one or both mandrel faces The wind angles achieved will depend on the options set The software displays on the screen the wind angles that will actually be used These angles are referred to as THETAI THETA2 THETA3 and THETA4 these are as follows THETA1 Wind angle on front mandrel face on forward carriage stoke THETA2Wind angle on rear mandrel face on forward carriage stoke THETA3Wind angle on front mandrel face on return carriage stoke THETA4Wind angle on rear mandrel face on return carriage stoke If hoop winding 90 is required the user can specify THETA as 90 The software will automatically generate wind angles such that the carriage advances fibre band width per mandrel rotation Read the special notes on hoop winding Required Wind Length WLREQ In general there will always be some scrap material at the ends of
44. largest overall speed allowed FEED MIN smallest overall fee rate allowed FEED DEFAULT START Speed for start position FEED DEFAULT WIND Winding speed FEED CALC METHOD only used for machines with a non standard speed calculation MAX MANDREL SURF SPEED the maximum speed of the mandrel surface at the largest diameter radius in mm min or inch min dependant on units 53 Cadfil Help 8 53 V7 63 Thus the maximum mandrel rotation speed in degrees min would be MAX MANDREL SURF SPEED 360 2 PI Rmax where Rmax is the largest radius of the mandrel being used If this option is set the maximum mandrel rotation speed is reduced as the mandrel diameter increases This is useful for two reasons it is safer for the mandrel drive train by reducing excessive load for large mandrels and it also limits the fibre delivery speed as high speed can lead to poor fibre wetting or other fibre delivery problems If the user wishes to use this feature to set the mandrel speed then FEED DEFAULT WIND should be set to a large value If MAX SPEED AX 1 mandrel axis has a lower value than the value calculated from MAX MANDREL SURF SPEED then MAX MANDREL SURF SPEED will also have no effect as the lower speed limit would always apply MAX MANDREL SURF SPEED ON takes a value of 1 or 0 If it is 1 then the MAX MANDREL SURF SPEED is considered of 0 it is not used The normal default unit of length in Cadfil is mm and LEN_UNIT_NAME MM is se
45. medium and low tension This function inserts the value of tension defined RMAX Maximum radius in the current mandrel only valid for axisymmetric mandrels RCLR Default mandrel clearance distance from current payout file ANR TXT BLOCK START POSN This is a special logical which is found in the MPF block definition and inserts a line or number of lines that define the start point and subroutine call for the SPF This is defined as a separte block as a program with multiple subprograms will use this block several times To understand this function is is easier to look at a working example of an SM file CADFIL VERSION Current Cadfil Version e g 7 34 PAY FILE NAME 44 Cadfil Help 8 53 V7 63 Name of current payout path file BANDWIDTH Width of the fibre band for the current SPF payout file XDAT Mandrel Xdatum value USER NAME Name of logged in user reported by windows FIRST SPF ONLY This is a special function variable In the program block definitions and line contain this value will only be processed on the first occurrence This could be used for example in the start position block to have a stop code NC M00 for the first SPF start only to tie in the fibres DTIME Incremental time for current motion WTIME Current winding machine time from start of program to current position TOT FIB LEN Total length of fibre wound in program
46. might contain M98 P7001 L126 Sub prog 7001 repeated 126 times The second NC program created might contain M98 P7004 L126 Sub prog 7004 repeated 126 times The subroutine 7004 can be added to the first program and the call inserted to give M98 P7001 L126 M98 P7004 L126 94 Cadfil Help 8 53 V7 63 If several layers are required then use M98 P7001 L126 First layer M98 P7004 L126 M98 P7001 L126 Second layer M98 P7004 L126 1 7 10 SPAR Winding 1 7 10 1 Spar Winding Prismatic non round sections The SPAR winding software is found on the QuickCAD main menu if optionally supplied This allows the winding of non round sections of constant or near constant section The section should not have concave portions as these cannot be wound successfully There are a number of options accessed from the menu dialog shown below Spar Winding Main options Spar High Angle Turn on Spar section spar Low Angle Turn across end plate Spar Low Angle Turn across End Dome Low Angle Turn across End Dome devt e See 1 7 10 3 typically 40 90 degrees is where the mandrel ends are not over wound and there is a turning length at each end of the mandrel the length of which is controlled by the friction parameter Generally if the wind angle is less than 40 degrees the turning length which may be scrap material tend to become impracticably long Note that for hoop winding it is quicker and simpler an
47. off on the Format menu The SM file contains comments describing all the parameter and variables in it A number of sample files are usually supplied It is normal for CCL to configure the default sm file to the best knowledge we have available at the time the software is supplied We can offer technical assistance on this if required please ask If you are unsure do not modify this file and always make a safe copy of the original file before changing it There are three types of data in the SM system constants which are variables i e constant name some of these parameters are described below There are some contants that define the program layout and this can contain variables These variables have the format variable name for example DATE during the post process run time this variable would be substituted for the current time amp date A list amp description of logicals can be found under the See 1 6 3 GEARING AX n These are the ratios which relate the units of of the winding machine The post processor uses rotational units of degrees thus if an axis rotation of 1 degree corresponds to a rotation of 234 567 machine units then the scaling ratio would be 234 567 If the rotating axis units on the machine are degrees then the scaling factor would be 1 0 For linear axes e g cross feed these relate the units used to define the mandrel in Cadfil to those of the machine i e if the machine uses mm an
48. often have the rotating centre of the yaw not at the fibre dispensing point When the head yaws the post processor must compensate with cross feed and carriage movements The total rotating length from the dispense point to yaw centre is made up of the FIXED OFFSET POLEN The fixed offset is a constant for the machine and is internally programmed into the post processor and will not change If there is no yaw axis set the offset to 0 00 MAX AX 3 INCR The yaw axis moves the head on a circular path The cross feed and carriage axes have to make compensating moves As the axes move on a linear path point to point if the yaw angle is large the clearance of the dispensing point could temporarily increase or decrease during the motion If clearances are small this could cause a clash with the mandrel The max increment can be set to 10 degrees for reasonable accuracy Any larger yaw movements are then broken into smaller parts and the correct carriage cross feed motions calculated for each If the max increment is set to gt 2 yaw axis limit the feature is fully deactivated PIPE MAX CARRIAGE INCREMENT The parameter is not strictly a post processor variable as it affects PAY file creation for pipe winding Multi pipe Pipe Hoop Multi hoop Where there is a long linear section of motion along the pipe with only 2 axes of motion for example of a helical winding of a 12000mm long pipe there could be a linear single motion block of 11000mm thi
49. positions in the program The dwell split feature allows the dwell to be biased between the ends 100 0 has all the dwell at the first hoop position and 0 100 has all the dwell at the second last hoop position Dwell split is only available if dwell winding is selected Currently this feature is implemented for Cadfil Axsym pipe winding dome vessel and vessel with end caps For other options it is ignored The Default split value is 50 50 but this can be changed by setting the DWELL SPLIT in the SM file See 1 6 2 SDWELL SPLIT takes value 0 0 to 1 0 Dwell winding has advantages and disadvantages as follows Disadvantages It leads to an extra increase in thickness at the turning points In general it can only be used when the hoop points are on a cylinder otherwise fibre slip will occur 33 Cadfil Help 8 53 V7 63 The exception is when the dome end on the cylinder has pins or has a shaft that the fibres can wrap around to prevent slipping In this case the end cap winding is usually not part of the final product Advantages Can give greater choice of band pattern Does not modify the wind angle on the rest of the path to achieve a band pattern Can be useful on some difficult mandrels see below Use of dwell winding on some difficult mandrels In this example the winding angle on the cylinder is low and using geodesic winding the fibre passes onto the end shaft without turning as in the first picture To wind this part
50. rotation is dependant on if the fibre track was started going up or down the screen The head geometry may dictate which option above or below works best For 6 axis winding using the correct value of See 1 6 13 4 is essential as when the yaw axis is moved there must be compensation in the carriage and cross feed axes due to the rotation not being centred on the end of the delivery eye Using the six axis post processor and when viewing along the winding axis the fibre from mandrel to payout point on the head has no component of direction in the Y axis and the fibre makes a 90 degree angle to the payout roller viewed along the axis of the roller This post processor asks for The 6 axis transformation angle the default value is 90 The user can specify the contact angle of the fibre around the payout roller Values less than 45 degrees are not recommended The best value is 90 but in some instances where there are problems due to limited vertical travel Other values between 45 and 90 can be used to reduce vertical travel 1 6 11 The 6 axis post processor 2 The alternative 6 axis post processor is similar to the See 1 6 10 except that the payout eye is constrained to move in a plane that contains the winding axis that is inclined at an angle to the X Y plane This can allow a larger diameter to be wound than is usual or my give better clearance if the payout head has an unusual configuration The angle of inclination is from the value en
51. should follow on the same line as this data item The user should now select the POST PROCESS option See 1 6 1 as exactly as for the CADFIL I software with the following exceptions 1 The user is not asked to select a band pattern as this has been pre determined by the software 2 The software allows the program cycle to have a different carriage position at start and finish to allow for band indexing along the mandrel 3 The initial codes may be different for the program start position as unlike standard axisymmetric winding the initial rotational position of the mandrel is very important Details on the use and configuration of the post processor can be found in the CADFIL user manual See also notes on See 1 7 9 4 and special considerations for See 1 7 9 5 See 1 7 9 3 1 7 9 3 Plate parametric error messages Many of the error messages produced by the software should be self explanatory a few need further discussion which is given below WINDING PATH IS TOO LONG FOR THE PLATE PATH GENERATION ABORTED This message is given if the plate dimensions and other parameters produce a winding that is longer than the mandrel There are a number of ways of removing this problem For example make a longer mandrel remembering that if the mandrel is to be rotated about the other axis also the length must not exceed the maximum mandrel diameter of the machine Other alternatives are to ask for a shorter sample length or to set the
52. spacing is small End Plane X position amp 2 These values are not used and will be greyed out Dwell Hold radius not used Bandwidth is the actual width of the fibre band to be used This is used to calculate the number of carriage circuits required for a layer and is also used for the graphics of the banding structure End turning length Not used Friction coefficient Mu Not used Wind angles Degrees is the value in degrees that the user requires in the central portion of the wind path i e the total length excluding and turning zones The Low angle option does not have a turning zone as the fibre turns on the mandrel ends thus the wind angle is fully up to the mandrel end Payout clearance and mode This feature is no longer used as the clearance is always from the DXF file as this is the most general and flexible method Mandrel Direction check box If ticked default the program is generated such that the mandrel rotates in the positive direction End Zone Speed Over ride This options is not currently used The function is to apply a factor to the winding speed in the turning zone 109 Cadfil Help 8 53 V7 63 Boss Rotation Angle see the elliptical boss dimension text above for details 1 8 Error Messages 1 8 1 Introduction to error handling There are two types of systems errors those which cause the system to terminate See 1 8 2 and those for which it may be possible for the user to make some corr
53. that Email Tabs couaplsmmultidayer Prosigip www cadtilcom CNG Tank example Page 1 of 22 30 From the NC Post Process Menu pick the Combine Programs Option top right picture The Edit Modify combined Winding Dialog will pop Sean right picture 2 26 Sit ma AAAA BeNOR Si SAH HBAS cach program file ere aA key information we eed for the joining path is ie end X position for nt RHRB AN FCN BRACE Paigh PAo i caret HE tps hs alo ou will be prompted to save the combined program if a p ram ehe dels Joining 4b UG WB on f or ee se in a PRSE X position of 255 0 to match the position of the end of the hoop winding 33 Repeat ADD for the fileV120P03 PAY for the low angle program os we could pick the Open option to retrieve a list that has 2 z 2 8 slide al at 90 wind angle and are on a cylinder the geodesic would just circle around the mandrel with no axial movement We need to apply Email desaite headfindomegle aWdetteer the piphtowheckehitrodlocANGA Oarthexbhiptad capagdh drefth2 low angle wind starts 41 From the Fibre Create menu pick the Friction step option OR left mouse click on the Cadfil Text Window Both will pop the step friction me to the right 42 Click the LH friction to set left hand deviation and set the friction to 20 and then click OK to close the dialog 2 29 hohe Se ee can see that for a 15 degree wind angle the left a be WEE E Hsiao ec
54. the path is shown to scale as a band of this width on the mandrel surface See 1 3 13 24 Cadfil Help 8 53 V7 63 1 3 12 Friction amp Step Dialog Set Friction Geodesic Friction Percentage Create Delete Step Help C LF Friction 0 000 1 r BH Friction Friction Coefficient Fix Point 0 120 UnFix Point This dialog sets parameters for See 1 3 10 to aid steering it across the mandrel surface C Constant Angle LH Friction Sets Left Hand friction The See 1 9 6 is when looking onto the surface of the mandrel facing in the direction in which the path is being created thus LH friction deviates to the left and RH friction to the right When friction is selected the user is requested to enter the friction percentage a value from 0 100 which can be entered in steps of 0 1 e g 33 1 This is the proportion on the friction coefficient a value the higher the friction value the more rapid the change in fibre direction Geodesic This option sets zero friction i e the path will continue geodesically RH Friction sets Right Hand friction See LH Friction Const Angle This option forces the fibre path to continue at a constant angle this angle being the current angle This option cannot be set on the first point of a fibre path This option is useful for winding along mildly tapering cylinders where it would be difficult to keep progressively changing friction to maintain a wind angle Warning at pre
55. the winding The software will generate a winding program that gives the winding angles over a rectangular area that is the Required Sample Length x the Plate Height In some cases a longer sample of full winding can be cut from the plate but of reduced height Fibre Band width BWID 90 Cadfil Help 8 53 V7 63 The band width is the actual width of the filamentary material that is being wound onto the surface It is usually specified in mm Large band widths will lead to less flexibility in exactly obtaining specific wind angles as the band progression will be greater Plate Height PHITE Plate height is the mandrel rotating diameter when winding and is usually defined in mm This value must be correct for accurate generation of winding programs see Figure 20 Plate Width Length PWID This value is the length of the plate along the machine carriage direction when winding and is usually in mm The value is used for checking that the mandrel is sufficiently long for the sample size requested see Figure 20 It is also used for location of the carriage over travel limits see CLREND Plate Thickness PT This is the thickness of the plate used usually in mm It us used in the calculation of mandrel clearance and for the radius assumed at the plate edges see Figure 20 The axis of rotation of the mandrel is assumed to pass through the geometric centre of the plate Top Side and End Clearances CLRT CLRS CLREN
56. to wind a single circuit starting at one point ion the mandrel and finishing at a different position Thus a user could generate a standard winding Pattern to wind a low angle layer on a component He could then generate a separate pattern for a high angle wind and he could then generate a joining path to allow the machine to automatically wind from the end of the low angle wind to the start of the high angle wind The wind sequence of patterns is specified in a See 1 5 1 such that the See 1 6 1 can automatically create a complete program for all the layers A See 1 3 3 in the same way as a normal fibre path The user generates a path with two or more hoop points turning points as shown below 28 Cadfil Help 8 53 V7 63 Cadfil Graphics Window Patel Ea FOUL HAL NOAS HARITA MERR tit Hoop Point The difference is that when the Payout path is created there is no band pattern there is only one cycle and the return half of the path is not created The joining path starts at the first hoop point in the path and finishes at the last hoop point See 1 3 7 1 4 Payout Path Creation 1 4 1 Introduction to payout path creation This module maps the fibre path from the surface of the component onto a notional control surface on which the winding machine is constrained to move The control surface or envelope gives clearance around the mandrel See 1 9 11 is created if the user does not create one In the See 1 2 1 of
57. wa IN A Start on this line l MA A W i AY VLAAMS FAAS ARON If you pick No to the start on this line prompt all the patch edges near the mandrel point picked will be highlighted in turn Pick a line on the Y 0 in the X direction on the centre line 3 When Prompted set the starting and to 90 degrees this is in the hoop circumferential direction Using Friction the path is steered across the surface of the cross piece and up the surface of the leg The path is shown in the follow figures It is important to Note that the start position blue filled square is on the Y 0 symmetry plane and the finish position hollow blue circle is in the X 0 symmetry plane Having made a template file save it via the finish amp save option the path will be given a FIB name extension The template path in now complete The next step is to make use of the See 1 7 7 3 as ee Be ee ELI E ae 297 ee a a AR ee a Se ee ee Y i LLige a ee a a a E E T E N o ee EXEAT E i et tT EI oie sess Gy a BS ETRY SS a a a a Se a a a ee ee ee E E TAA 1 7 7 3 Tees Using symmetries In a previous section the creation of a See 1 7 7 2 is described In this section we use symmetries to expand the path the figures used are a continuation of the data shown in the previous section 82 Cadfil Help 8 53 V7 63 From the Tee Dialog select the Reflect path X 0 option
58. 000 Ees lt ibre Band Width 25 000 i es Start Position from Chuck Ret Pt 300 000 a Fibre band data 3000 000 The thickness Total Length Of Winding Calculate updates for each Friction Coefficient e g 0 2 0 150 Update layer to keep the Mandrel Rotation 1 1 1 i winding angle accurate Data that is constant for each layer Cylinder radius Is the radius of the mandrel at the start of winding If the mandrel diameter is 200mm the radius is 100mm Clearance Radius is the distance of the payout head fibre comb or similar from the mandrel rotation centre so if the mandrel radius was 100mm and the clearance radius was 150mm the machine payout head will be 50mm 150 100 from the surface of the mandrel For machines with more than 2 axis this position can be set automatically in the NC code For 2 axis machine this must be set manually or a value that is possible or fixed on the machine must be entered If the machine is a large distance from the mandrel accuracy will reduce variation in wind length and band structure For large mandrels more than 1m diameters a surface clearance of 250mm 10 inches is OK For small mandrels lt 300mm diameter a surface clearance of 50 75 mm 2 3 inches is OK Fibre band width is the true width of the fibres band as it lays onto the mandrel if you considered it as a tape The Band thickness is the thickness of the fibre band as it lays
59. 1 7 7 3 is described In this section replicate existing paths by creating a parallel paths The are 1 83 Cadfil Help 8 53 V7 63 band width away from the previous path on the mandrel surface Pick the parallel path option from the Tee Dialog shown below T Winding T Mandrel Generate Make Template Path Reflect Path X 0 Reflect Path Y 0 Parallel Path Convert Pipe Payfile You will be asked for the name of he FIB template file Having selected the template path that has had symmetries applied to it you will hen have to select the side that the path is when prompted The parallel path is then s calculated progress is indicated ion the screen The display should look as below E hi ze T PRI eS hee ie a PA 4 NT REBEL ivan Hoth The path is then saved put the second path can be used to generate a third path in the same way and the third path to create a fourth After saving a fibre path you can proceed to the Create Payout Path Option when prompted Alternative a payout path PAY files can be created from a FIB file at any time by using the Create Payout Path option from the Cadfil Main menu The payout path process for Tees is described in following section 1 7 7 5 Tees Payout Path In a previous sections the See 1 7 7 2 for Tees is described In this section the create of
60. 1 9 4 have been generated completing the path requirement for CADFIL Alternatively the user can start the fibre as mentioned in the previous two sections and the user can steer the fibre through the section in question by using the friction facility of the software See 1 3 10 2 3 Parallel Datakey DK12 2 4 Viewing Options Dialog 147 Cadfil Help 8 53 V7 63 2 5 Endcap Types amp amp Parameters Quick CAD Mandrel Geometry Help Cylinder Radius R1 100 000 1000 000 Right End Cap Oylinder Length L Left End Cap f2 Elliptical 7 fz Elliptical M R2 10 000 10 000 Winding Parameters Material Data Wind Angle A 0 90 Band Width 0A JO Non Geodesic End Opening Radius Left End Opening Radius Right Envelope Geometry Help Tl 2 Axis Mode _ Oylinder Clearance C1 20 000 _ Axial clearance C2 ji Right Shaft Clr SR 70 000 20 000 20 000 Left Shaft Clr SL Joining Path End Position Joining Path Start Position Dome End 1 Parameter Elliptical End 2 Parameters CALCULATE Torrospherical End 3 Parameters Usually R3 gt 2R1 amp R2 0 1R1 approx 148 E lt J Cadfil Help 8 53 V7 63 2 6 Slide 1 2 7 2 8 lt header amp 13 date time 2 9 Click to edit Master title style Cadfil is a registered trade mar
61. 15 Mandrel used in fibre generationLine Format 1X A16 Number of Elements used for Fibre GenerationLine Format 1X I5 Number of Points in Fibre File Number of lines below Line Format I5 FIBPLN FIBPOSx FIBPOSy FIBPOSz FIBDCSx FIBDCSy FIBDCSz Where Format FIBPLNNumber of plane on which fibre is travelling I5 136 Cadfil Help 8 53 V7 63 FIBPOS Fibre X Co ordinate F11 4 FIBPOSyFibre Y Co ordinate F11 4 FIBPOS7Fibre Z Co ordinate F11 4 FIBDCS Fibre X Direction Cosine F11 7 FIBDCSyFibre Y Direction Cosine F11 7 FIBDCS 7Fibre Z Direction Cosine F11 7 1 10 2 5 Payout path file PAY The Payout Path Generation section generates files with a PAY extension These files contain data relating to how the fibre file was generated 22011111 CON1 MND 42 24 120000E 02 250000E 02 160072E 02 192 345 506 000 49 246 0016070 9999890 0044151 0000000 0000000 0000000 345 606 62 076 49 520 000 345 373 6 371 48 881 0400366 9931564 1097148 0000000 0000000 0000000 342 866 68 557 42 011 000 344 972 12 673 47 789 0816015 9716734 2217928 0000000 0000000 0000000 339 805 74 209 33 742 000 344 301 18 836 45 976 1230061 9360252 3297368 0000000 0000000 0000000 The data contained within the file has the structure as outlined below Line 1 ID C1 C6Format 16 6 1X 11 ID identifies the package or sub package that generated the file C1 C6 May not always be present They relate to the axes
62. CADFIL there are a number of ways in which the thickness of a component can be built up The various methods for modifying the thickness of a wound structure easily are described below Bandwidth 34 Cadfil Help 8 53 V7 63 The first opportunity to modify the thickness in the CADFIL design process exists within the See 1 4 2 section in that bandwidth values can be varied to attain overlaps or gaps For example the bandwidth of a fibre bundle on the surface of the component is say 15mm We could inform the CADFIL system that the bandwidth of the fibre on the surface of the component is 5mm The CADFIL system would calculate the NC program with its band shifting allowing for a fibre bandwidth of 5mm Therefore there will be a 10mm overlap between adjacent bands on the surface of the component hence increasing the thickness of the composite Informing the CADFIL system that we have a bandwidth of greater than the actual fibre on the surface of the component will result in a component of basket weave or one which has holes Number of cycles for coverage The next method which enables the thickness to be modified is to inform the system that we require a different number of cycles for coverage in the See 1 9 8 pattern dialogue than the value calculated as the minimum number from CADFIL The CADFIL system determines the minimum number of cycles for complete coverage of the component given that the bandwidth of the fibre that was e
63. Cadfil Help V7 63 Cadfil Help 8 53 V7 63 Table Of Contents I CADRFIL Help Systemi di oen arer eree a ar er OVE E A eee TEDES E E E AS 4 T AMGetting Started aaia e T E E T E E EEEE 4 BD AOU Caidil ara a E T A N T A r 4 Bele Wat 1S Sait yosi eina ei cad atest ea al staat Sand a aa a eaS 4 1 1 3 Jpstallation epee ee ete ar ge ee ee eee 5 1 14 Software Updates Ssss sinni noai KE R or eoit 7 1 1 5 Stages of program Generation esesessesessreesessissresressessresrerressresressersresrersesse 8 1 1 0 Licence bile EXPY o rn a R E E Ea ETE EEN 9 Bel Mate al Databas si ea a a E R seed hte chee 9 1 2 Mandrel Creation sis cerisiers ertasini isoine to iser isita cea aeeteee 12 1 2 1 Overview of Mandrel and Envelope Creation ceccceeesseeeeseeeeeseeeeeneeeees 12 TDD Mandrell X RY Edit zeis ss deed R Ea T E EE A i 13 1 2 3 Importing a DXF TG yecssesciicnencaetnuends cosh ERE RT NE 15 1 2 4 Converting Old mandrel files sseauleccsttectesniadeuniue wali 16 T3 Fibre Path Creat onsuinnnnie nanea E a ea ds E aaa 16 1 3 1 Introduction to fibre path generation ssesesssesssessessseessersseresseesseresseessens 16 1 3 2 Mandrel Meshing for fibre path generation sssssssessseesseressressesssereseressers 16 1 3 3 Fibre Path Start Positlon sssccsiscnnstenni ineeie 17 13 4 Winding Tra j torie Siinne non r a aa E e ET eoa 17 1 3 5 CADFIL Fibre Path Reg uiretmments ou s5ay ssa 3s cuutpressteadewarvedpete eordooeutnawaaenads 18
64. Consider the band edge and 40mm if we consider the Email HRN a KAKE ing tfid She at both ends and is fixed by postin ly ade To 2dlidvsithg es eee can be viewed as illustrated on the next required To achieve a very stable transition ea rathe ti n and then Pick Hoop Up 39 All Cadfil programs f a Bik Sr ef fe geri 10 ani ARPT an 10 dialog below we pick Email SWRA ING lutea ti ajala ane nikasie havsapaspeq abe turning point on the LH We ROW need to Teverse o te Ete st ke Hokateds yaon ti SER ea wenkiowe turned on the RH end cap as can be seen on the next the text y th ind angle decreases with each step Hin from R ip IncuoR aaa Au She inter g clicks we have turn on the LH end cap again as can be seen on the next page y D 11 2 31 ee wind angle is 41 degrees but given the path we are Email walenGoatihaomas 15Webiees at Hiip puneekactileartot ENG Tank example Page 7 of 22 difference To speed things click on the text winding to pop the 2 32 SGA e use the Test Hoop Email Ptgafdpaeasageymwe capyage that tft Iwww cadfil com CNG Tank example Page 1 of 22 last turning point 4 is at X R 18 which is close to our target position If we needed to improve we could 5 ht Wes on the graphics window a k We ALR BOW aiietbe sbeUbaiewing options from sii little and then REL helat SieRe dicted igk ihfsegombine Programs RhoA HSiAMted QU BSOHGES EE tH Shick the open button and open the V120 CTL
65. D The calculated machine positions in the PAY file lie on an elliptical surface See Figure 20 around the mandrel when view end on along the carriage axis This allows close control over the fibre whilst allowing clearance to be made between mandrel and delivery system There are three parameters Clearance Top Edges Face Clearance and End overshoot clearance These are shown in Figure 20 These values are normally in mm Start Position from Plate End XSTART This is the location of the start of the winding pattern on the plate relative to the most negative edge of the plate with respect to the carriage axis positive direction and is normally in given in mm By changing this value the position of the winding on the mandrel can be changed This parameter permits a positive or zero value however if a negative value is specified the program will automatically fix the program start position such that the centre of the useable sample is at the centre of the plate This facility is useful if a number of different wind angles are used as the usable portions of each program will thus have maximum overlap File stem name The first line on the control file contains the stem name for the data files the software will create For example if the name was PLATE1 the software will create output files PLATE1 FIB and PLATE1 PAY and the default NC data file will be PLATE1 PRG 91 Cadfil Help 8 53 V7 63 Because this item is read as text no text
66. E E E EEEE 147 2 3 Parallel D tak y DKI 2J rre E Sa easel ERE E R E A ale 147 2 4 Viewing Options Dialog ssssesesesesesseseseeesseeeseressresseressetesereseressressereseeesseressee 147 2 5 Endcap Types amp amp Parameters s ssesseneseeesseesseeesseteseressresseesseeessersssressee 148 220 SME EE E E 149 P TEITE VEEE A O E A ERA E T N 149 DS MEAG GEHL a r e a a aai a A A E E O 149 2 9 Click to edit Mast r titl stylessrecsicieniiesnninernn in 149 2 10 notes flas if Notes akc csaascteut sens en soma Ta A eaasuteatam tele 149 NT Slde Toeren a a a e ie aia E 149 PAESI E E A E EAE E AEE E 150 De WD Side hin enoaan n aa i a Tn a en sneen s oai 150 eM idel etsy vielen ole nel lt Scale oe E T den a E 150 DVS ICS EA EEE sacagicres yaa A E a seas cea sas cma atoaneearsunaniohte 150 DMO SUAS les eocsaecaszesestecey A tans shaded a aed earies aA E te Saa E TT aes 150 DMT SIS E votaiacesetuwess eter void eva cetosecaite E 150 DNB SIGS Tae esi diess e ee eG RR eE 150 219 SITS Wane vetted lt cvs ace weeps lea vst ve ogists oasis 150 2 20 SHIGE Torii ier a EA EE EE EE eae wees 150 Dy Pel Side lamg n a a e a E A E E A aa E E 150 222 SITE lana e E sats tes aE E a EE A E E R 150 223 Sude Ui Stas ce a eee en ee a 151 DPA SUAS lt Lsas cecal EE AA TTE ATT 151 229 Slide Tienaa a E E e E a E MG as E ante 151 DOI ae E A e AE RS 151 22T Side larrara in N E E E E A R 151 2 28 Slide Torate enner ian a a ia Eaa a Ea aaa aaaeaii 151 DD OS MGS li
67. Fl length of fibre between mandrel and payout eye Friction coefficient Mu used to turn the fibre in the cylindrical parallel pipe turning area at the ends Wind angle degrees Alpha Band Phase Adjustment Angle In Degrees Phi If you made an elbow winding for a specific wind angle say 55 degrees and then wanted to wind a second layer then is would wind exactly on top of the first layer with the bands being placed directly on top of the bands from the earlier layer Like building a wall from bricks it is better to stagger the joints so the edges of the bands are not on top of each other If the first layer has 12 circuits to make a layer then each band occupies 360 12 30 degrees of angle so if a band shift of 30 2 15 degrees will give maximum band stagger 74 Cadfil Help 8 53 V7 63 Quick CAD QuickCad Elbow Winding M 2 Asie Mode E NowGeodest E Mandrel Radius Cancel Centre Line Bend Radius 600 0000 Read P ead Param s Bend Angle Degrees 0 90 30 00000 Parallel Length Both end 400 0000 Write Param s Wind Axis Position 300 0000 CALCULATE Number of points per rotation 12 Fibre Band Width 12 00000 Help Free Fibre Lenath 450 0000 Friction Coefficient e g 0 2 lo 2000000 Wind Angle Degrees 40 90 45 00000 Mandrel Direction 1 1 i _X From Previous Pay File_ Band Phase Adjustment degrees 0 000000 _XFromNextPayFile m Note that care selection the winding axis offset and free fibre le
68. Mandrel Carriage Crossfeed Vertical Eye Roll Eye Yaw respectively They take values of 0 or 1 a value of 1 indicates that the post processor will force the cycle to return to the initial position at the end of the cycle for that particular axis Line 2 GMANFormat 1X A16 137 Cadfil Help 8 53 V7 63 GMAN The name of the mandrel surface definition file used Line 3 NCY NELE CLR BWID ROTNFormat 2 1X 1I5 3 1X E13 6 NCY Number of winding cycles NELE Number of elements per revolution on axisymmetric mandrel CLR Default clearance value BWID Bandwidth used ROTN Total rotation of path in radians Line 4 NPAYFormat 1X 15 NPAY Number of Points in Payout Path File i e number of 2 line records following Line 5 F1 F2 F3 D1 D2 D3 N1 N2 N3Format 3F10 3 6F10 7 F Is Fibre position on surface D Is fibre direction vector N is surface normal amp 1 2 3 relate to the global X Y and Z axes N may not be set for some packages Line 6 P1 P2 P3 LFormat 4F10 3 P1 P3 Payout Path position X Y amp Z L is fibre length from F to P Lines 5 and 6 are repeated NPAY times for successive points 1 10 2 6 Thickness data file THK The Payout Path Generation section also generates thickness files These are generated with a THK extension This file contains data relating to how the fibre file was generated 111 REVIEW MND 244 2 377622 5 000000 LI XR ANGT 1 122600E 04 612500E 02 900000E 02 952736E 01
69. RPIPE WINDING GEOMETRIC PARAMETERS The first four parameters end position and radius give the size of the mandrel and its position relative to the machine datum usually the chuck face The next two parameters Clearance radius and Mandrel surface clearance distance depend on the status of the 2axis mode tick box and are shown in the following diagram For the 2axis options the clearance radius is used and thus the cross feed axis is not used The other option uses a clearance from the surface of the mandrel and thus the cross feed is used This gives better control as the payout eye is usually closer to the mandrel along the full length 67 Cadfil Help 8 53 V7 63 TAPER PIPE WINDING CLEARANCE PARAMETERS 2 axis mode v Es E Sg oO The remaining parameters are exactly as described in the Cadfil help manual for QuickCad Pipe winding Please note that the wind length specified is made up of a turning zone at each end these are of different lengths and a zone at the user specified wind angle These lengths are reported along with any error messages in the Cadfil text window 1 7 3 Cylinder Hoop Winding 1 7 3 1 Hoop Winding Hoop winding is the simplest form of winding and can be easily programmed manually on most winding machines The QuickCad Hoop winding options generates hoop winding programs and Pay files for visualisation based on user specified parameters The hoop winding produced by this program is a doub
70. Shaft Radius Write Param s Shaft Length Minimum are length around Section End Plane x Pos 1 Extra Dwell Dist End 1 End Plane x Pos 2 Payout Clearance Mode Extra Dwell Distance End 2 G Envolopa fram DXF Dwell Hold radius Payout Clearance Band Width o o End Turning Length Wind Angle Degrees V Mandfel rotation in direction Friction Mu e g 0 2 ivr Cua rame Browse DXF Files End zone speed over ride Boss Rotation Angle Note that of the parameters may be greyed that is the user cannot select of enter data This is because those options are not used and are retained for compatibility with different software options or for future options Mandrel Start X Start and Mandrel Finish X These define the length X finish X start of the constant section of the mandrel and where these sections are positioned relative to the mandrel origin the x 0 position The position of mandrel origin in the machine will depend on the machine datum s and the XDAT parameter described elsewhere in this help file under post processing The dome length is is the length from the section where the mandrel start to change shape to where it meet the shaft This length is assumed to be the same at each end of the mandrel Minimum Arc length around the section is the typical spacing of data points along the path on the mandrel surface the units will be the same as the mandrel units usually mm or inch For reasonably accurate win
71. This option cannot be used to start on a cylindrical section at there are an infinite number of locations If the user does not select any of the choices or if no choices exist the software returns to the previous menu Having specified the start location select HOOP U or HOOP D The selection will fix the direction of mandrel rotation For example if the machine s positive direction of mandrel rotation was clockwise when viewed in a positive direction along the mandrel s axis of revolution then the user would select HOOP U in order that the instructions to the machine controller are not all negative In some cases when using the 5 axis 3 plane or the 6 axis post processors the mandrel rotation direction can be important if 21 Cadfil Help 8 53 V7 63 the machine head is not symmetric as these post processors use three Cartesian axes of motion XYZ Having specified the fibre path start position the path can be generated as normal with or without the use of friction If the path is generated fully geodesically the end opening diameter will be the same at the other end of the mandrel to within the accuracy of the numerical predictions If a larger or smaller opening at the other end is required friction must be used The path can be advanced and deleted over the mandrel end using different amounts of friction until the specific diameter is achieved This can usually be done in 2 or 3 iterations and is made substantially easier if a ma
72. X 3 in the SM file Depending on the machine the user may have to jog the machine axes into the correct positions and then zero the axes See 1 6 13 10 1 6 13 10 Running the NC program After the program has been transferred to the FWM it can then be run Programs are available from CCL to allow the transfer of NC data to and from the FWM via RS 232 serial protocols Instructions should be available from the machine builder and the controller manufacturer on the operation of the machine The payout eye should move to the start position and then stop The user must then attach the roving s to the mandrel The software assumes that the fibre is pulled at 90 degrees to the winding axis i e is at hoop The user must ensure that the attachment is consistent with the way the mandrel is about to rotate Small errors in the point attachment point do not generally have much effect on the winding pattern as the paths usually adopts the correct path within the first circuit When using a new program for the first time extreme caution should be used as errors in the input data could cause the machine to crash The user should initially set a slow feed rate and be prepared to stop the machine quickly CCL cannot accept any liability for failure to follow such advice 1 7 QuickCad 1 7 1 QuickCAD Parametrics Introduction The contents of the QuickCAD menu will vary depending upon which of the parametric options have been supplied Crescent C
73. XCEEDS 10 1 DIAGNOSTIC OUTPUT HAS BEEN MADE TO ERROR FILE Very long thin surface elements do not model the surface of the component very well as the fibre only changes direction at boundaries A check is incorporated into the software such that when the number of elements is entered the aspect ratio of the patches is calculated The patch length is more than 10 times longer than the patch width the above warning is given and some diagnostic data is written to the CADFIL LOG data file The user can proceed with the fibre generation and the windings will be perfectly satisfactory in a majority of cases The warning is provided so that the user has some awareness of this potential problem area A sample of the diagnostic output is shown below This data will be of use if the user wishes to modify the mandrel to remove the warning message In some circumstances this can be achieved simply by reducing the number of elements In other cases it may be necessary include new mandrel sections SECT1 and SECT2 are the points in the mandrel X R data to either side of the patch es for which the other data is provided If the radius at one of these sections is zero at the 113 Cadfil Help 8 53 V7 63 ends then there is only one patch type between the sections If the radii are non zero there are two separate patch geometries between the sections and hence two lines of data are shown If the radii at SECT1 and SECT2 are equal these lines of data are identical
74. ader information and show the units and item description Currently only the tex density and bandwidth values are used for calculation the other information is there for reference and for future use Category currently must be Fibre or Resin Type is Carbon Glass Aramid or Other for Fibres and Epoxy Polyester or Other for Resins The other parameters are standard material parameters that can be found in manufacturers technical data sheet The user can set material data from the Cadfil Main option menu or from the Material Properties button that occurs on various dialogues during program generation When the set materials options is selected the dialog shown below is displayed 10 Cadfil Help 8 53 V7 63 Material Selection Roving Type Resin Type Carbon X JE posy X Roving Description Resin Description 0012 Toray T400HB 6000 0058 Sample Epoxy Tex g Km GE Density g om3 14 Density g em3 Roving Width mm Modulus GPa Tensile Strength MPa Elongation Number of Filaments Filament Dia micron 7 Cancel The Roving type can be changed from the pull down menu The Roving description pull down will show all the rovings of the current roving type that are in the database A roving material can be selected by clicking on it from the pull down menu The same logic applies to resin type and resin description The current selections are the ones shown in the dialog and t
75. ailable by going to and you can download the latest update from this page Please note that the latest version of software may not run with the level of licence on your Datakey please read the following notes The Check for Updates Option will write to the Cadfil Text Winding and tell you a The current version of Cadfil that you are running b If an update is available c The latest Version that is available for download d The Highest version available that will run with your current Datakey licence settings If there is a version that you cannot run you may be able to get a free update for the licence on you datakey or there may be a charge Please contact us at with the details of your current version the serial number from the datakey and the name of your company If an update is available and can be used please go to and follow the instructions to download and install the update Cadfil Help 8 53 V7 63 It is possible to have several versions of Cadfil on a PC however the shortcuts on the start menu and desktop that are created by the installation program are for the last version installed 1 1 5 Stages of program Generation CADFIL comprises of four stages mandrel definition fibre path design and payout eye path generation and post processing The See 1 7 1 available for certain geometries complete the first three stages in one go Post processing converts the machine independent payout path into machine instructions co
76. am for example if 31 circuits are used per layer then changing to 62 will give two layers 35 Cadfil Help 8 53 V7 63 1 4 7 View payout path The payout path previously generated can be viewed by selecting the View Payout Path option at the main menu The viewing section enables the user to view from any direction the component and one of its relevant payout path tracks The payout path is shown as a series of payout eye points connected by lines This permits the user to view the motion of the payout eye relative to the mandrel The system requests the user to input the name of the existing payout path file The system will then read the path and mandrel data If payout viewing has been entered automatically from say a QuickCad payout data is already loaded The See 2 4 is then shown the options are as follows View OptionsThis allows the user to select different view directions to select graphics output to a printer and to use the zoom and pan facilities The use of this menu is as described in the section on See 1 3 13 StepSwitching the step option allows the path to be redrawn in steps or stages The next section is drawn by clicking the step increment This is a useful option for enabling the operator to view the progress of the eye around the mandrel when winding the selected path Rotate X Axis This option enables the user to rotate the payout eye path around the component the X axis being the components and the paths
77. andrel file can be found in the appropriate appendix X POSITION REPEATED IGNORED 111 Cadfil Help 8 53 V7 63 The message occurs when the user attempts to create a new mandrel point whose X co ordinate already has a radius specified The new X R position is ignored that is it is not added to the mandrel data To allow two different radii at the same mandrel position creates a step in the mandrel which it would not be possible to wind over If for some reason the user wishes to create a step in the mandrel for example on a boss at the mandrel end then X values that are very close to each other can be used STEP IN MANDREL POINT REMOVED When the mandrel data is saved or read some checks are performed on this data One of these checks is for a step in the mandrel that is two X positions that are equal and of differing radius If this occurs the first X R position is deleted prior to writing the data to the disk ZERO RADIUS IN MANDREL POINT REMOVED When the mandrel data is saved some checks are performed on this data One of these checks is for a zero or negative mandrel radius that is not at the end of the mandrel A zero radius is allowable at the ends of the mandrel but is not permitted at other locations If this situation occurs the offending X R position is removed as the data is being read or saved UNABLE TO OPEN THICKNESS FILE This error will usually be caused by the thickness file specified by the user not existing
78. andrel rotation with no carriage movement at the end of the hoop winding It can be zero Angular Point Spacing Deg This value determines the point spacing around the mandrel for generating the payout path If the user wished to view the hoop winding band structure in the payout path viewing options then use a small value say 20 degrees This value must be less than 180 degrees Mandrel Direction 1 1 Set this to 1 for positive mandrel rotation and 1 for negative mandrel rotation 69 Cadfil Help 8 53 V7 63 1 7 3 2 Multiple Hoop Winding Multiple Hoop winding is can generate a winding program that hoop winds between a series of specified positions on a cylindrical mandrel with an optional dwell mandrel rotation only at each of these points The QuickCad Multi Hoop winding options generates hoop winding programs and Pay files that can be used for visualisation based on user specified parameters These user specified parameters are Cylinder Radius This is the radius of the cylindrical mandrel Clearance Radius This is the distance of the fibre dispensing point from the axis of the cylinder This MUST be bigger than the mandrel radius Fibre Band Width The width of the fibre band used to determine the winding angle such that the cylinder is fully covered by one circuit i e the carriage advances one band with for each full mandrel rotation Angular Point Spacing Deg This value determines the point spacing around t
79. ape against the roller It does not remove any twist due to the slope of the component s surface If the user is winding on a steep cone or near the top of an end dome then there will be a temporary twist in the tape tow that can cause problems This problem can be reduced by increasing the POE clearance This has the effect of reducing the twist per unit length in the fibres but clearances may be too large and the accuracy of the fibre laying could decrease 1 6 10 The 6 axis post processor 1 This option can be selected from the post processing menu Operation of the 6 axis post processor is similar to the See 1 6 1 The roll and yaw axes are used to keep the tows aligned on the payout eye and to remove twist of the tows between eye and mandrel This allows wider fibre bands to be used without the band 49 Cadfil Help 8 53 V7 63 narrowing due to fibre twist when winding across dome ends Some twist is normally experienced with 4 axis winding The vertical axis is used to provided greater clearance between the winding head and the mandrel as the head shape on 6 axis machines means that positioning the feed eye close to a dome end is not possible due to head clash with the mandrel shafts If the vertical axis is not used a very long payout eye extension is required The position of the payout head will either be above or below the horizontal plane through the mandrel axis dependant upon the direction of rotation of the mandrel The direction of
80. aracter REM as the hot key for that menu option REM REM Some strings have items such as xxxxxxx or yyyyyyy These REM x s are replaced by a number value at run time Do not change REM the number of x s or y s but the position in the string REM can change REM REM Thank you for your assistance REM 00001 Invalid Envelope flag in mandrel file 00002 Invalid Symmetry flag in mandrel file 00003 INVALID NUMBER OF X R POINTS 00004 X R Mandrel array full 00005 Error converting mandrel data 00006 Non axisym generate not available 00007 You can Left Click the Graphics Window to Advance the Fibre 00008 You can Right Click the Graphics Window to Delete Fibre 00009 Option not authorised 00360 BAND WIDTH 00361 Machine data from file gt 10101 Main amp Options 10102 amp New Mandrel 10103 amp Mandrel Edit 10104 amp Fibre Path Create 10105 Create amp Joining Path 10106 Fibre amp Path Modify 10107 amp Create Payout Path 10108 amp View Payout Path 10109 amp RTM Results 10110 amp Exit 10201 amp Fibre Create Menu 10202 Finish and amp Save 10203 amp Action 10204 Se amp t step 10205 amp Delete 10206 amp View Options 10207 amp Path Display Options 10208 amp Rotate About axis 10209 Redra amp w 10210 R amp estart Path 10211 amp Friction LH 10212 amp Geodesic 142 Cadfil Help 8 53 V7 63 1 11 Examples 1 11 1 Examples Introduction The is a new section within the help file at this help level It i
81. arallel key DK12 is now obsolete 12 Cadfil version number too high for licence data version The above are the ones that you might see The DK12 datakey is obsolete at Cadfil Version7 25 Cadfil Help 8 53 V7 63 The error codes when installing a new licence file are different meanings these are 1 Lic dat file selected is not found 2 Error opening lic dat file 3 Error reading lic dat file 19 Lic dat file is corrupt 5 6 License file is time expired 7 DK3 found but not recognised 8 Wrong DK3 for licence file wrong licence file for DK3 9 11 12 DK12 error codes 1 1 4 Software Updates Cadfil is sold with a defined period of technical support the support period is usually 12 month from the time of purchase Modifications improvements and technical solutions to issues are published from time to time at the Cadfil web site Such new versions published within the period of technical support are available for download and installation As of Cadfil version 7 38 the facility to check for updates automatically is included on the Help Menu with the Check for Updates Option If you select the Check for Updates Option and you are automatically directed to this page then Cadfil could not make a connection to This could be that the the computer does not have an internet connection or perhaps and the Cadfil application is being blocked by a firewall such as the windows firewall You can manually check if the updates page is av
82. ation in the carriage and cross feed axes if this rotation is not centred about the end of the delivery eye 1 6 9 The 5 axis 3 plane post processor The 5 axis 3 plane post processor can be used for most components where the user wishes to use a payout roller It is selected where supplied from the Post processing menu It uses all axes excet the yaw axis The only real advantage over the See 1 6 1 system is that the contact angle of the tape tow around the roller is constant and equal to 90 Degrees The operation of the software is identical to that of the standard 3 and 4 axis systems except that the user is requested for additional input data this being i Control surface clearance This clearance is added to the largest mandrel radius and is then used to define the distance of a plane of constant axis AX6 vertoical axis This plane will be either above or below the mandrel depending on the direction of mandrel rotation 1i End plane clearance This defines the distance of planes of constant AX4 carriage from the first and last mandrel points These end planes are used to limit the carriage travel when winding lower winding angles The POE travels in the planes described above such that the POE is always on the positive cross feed side of the mandrel The Tape tow is held such that the contact line from roller to mandrel is always in a vertical plane The roll axis motion is calculated to remove the sliding action of the t
83. ava LIVHS END PLANE 2 SPAR PARAMETRIC PROGRAM WITH FLAT ENDS 129 Cadfil Help 8 53 V7 63 1 9 19 QuickCad Sphere Parameters CLEARANCE RADIUS SPHERE RADIUS a 2 a lt 4 _ a 4 lt a a SPHERE PARAMETRIC 1 9 20 Machine offsets and Datums Datum s are used so the winding machine can automatically move to the correct start position The values OFFSET AX x x can be axis 1 to 6 are constants and are put in the post processor configuration file SM file The XDAT value locates the mandrel in the machine and is given during program creation 130 Cadfil Help 8 53 V7 63 MACHINE AT HOME ZERO POSITION OFFSET Ax 4 CARRIAGE MANDREL ROTATION an CENTRE AX 1 ee tone eee eens FRONT VIEW SPINDLE DATUM ON CHUCK FACE OR SIMILLAR FIXED POSITION TOILA g9 X7 13S 440 EYE ROLL AXIS CENTRE AX 2 PAYOUT EYE DATUM 033455049 Sk LIS 440 TOP VIEW HLONST SAS LNOAY Na130d MANDREL DATUM ZERO POSITION CAN CHANGE FOR EACH MANDREL USED 1 10 Appendices 1 10 1 Cadfil Installation To install Cadfil the installer must have administrator rights on the PC for steps 1 2 and 4 STEP 1 Install Cadfil Cadfil comes as an executable install file When run the install file e Copies files to the C CadfiNcadfil7xx folder 7xx is the version number e g 7 01 would be 701 e Creates Registry keys e Creates shortcuts on the Start menu in the prog
84. axis of revolution This path rotation can be carried out in any view On selecting this option the user is prompted ENTER RELATIVE X AXIS ROTATION gt The payout path will be drawn in its new position either in full or in steps the path in its initial position remaining displayed i e two paths will be visible the original and its new rotated location DRAWThis option clears the graphics window and redraws with current settings The following options determine what is drawn at the next redraw Fibre BandsThis allows the user to see the band structure Fpath PmarkDraws the Fibre Path and Payout Markers for the payout points Ppath PmarkDraws the Payout Path with Payout Markers on it 2D Pay PathDraws the Payout Path with the points rotated into a common plane F gt P LinesDraws lines representing the fibre from the mandrel to the payout point These data is as it would be seen on a 4axis machine DEFAULT MODE Animate Staticlt is possible for the user to create a solid model representation of the fibre dispensing head using a number cylindrical and cuboid brick primitives In this mode the user can draw each position of the payout head around the mandrel for a particular payout path The payout block and mandrel are either draw in wire frame or solid dependant on the SHADE mode The head is rotated for the rotating eye and yaw axes The fibre band is also drawn from the payout head to the mandrel The band can 36 Cadfil Help 8 53 V7
85. be launched automatically from the Cadfil Pipewinder Multi Pipe dialog if these options have been set 1 6 13 Post Processor Input 1 6 13 1 Post processor input The post processor asks the user a number of questions these are The name of the payout path PAY file to use The name of the program file PRG to create XDAT See 1 6 13 3 to locate the mandrel in the machine The Payout eye extension length The feed rate calculation method and winding speed The See 1 6 13 7 for the main program if required The NC part program number for the subroutine if required These are explained in more detail where necessary in the following sections In most cases the data is checked for validity and the user is asked to re enter invalid values See 1 6 13 2 1 6 13 2 Entering names of PAY and PRG files When entering file names in the post processor the extensions e g PRG in lt filename gt PRG etc should not be added When asked for a payout file if the user entered test dat the program would strip the extension input and append the default extension and then search for TEST PAY If he entered TEST then TEST PAY would still be searched for Input can either be in upper or lower case but lower case input is always converted to upper case as some NC controllers do not accept lower case characters 51 Cadfil Help 8 53 V7 63 If the payout path PAY file is not found in the current directory then the u
86. been produced and tested using this method The user defines the sphere geometry radius and end opening radius and material parameters such as the band width and the number of individual winding angle that are required The program then creates all the necessary winding path information and transition paths that wind from the end point of one path to the start point of the next The parametric program is invokes from the QuickCAD options of the Cadfil main menu This is documented elsewhere in this manual A sample file call SP1 PAR is supplied in the EXAMPLES directory The program generates a series of PAY files for example if the parametric data was in the file SP PAR the software would generate SP01 PAY SPO2 PAY SP03 PAY A maximum of 99 payout files can be created Note that on DOS systems the maximum filename before the extension is 8 characters and hence the stem name the user supplies should not exceed 6 characters A special control file SP CTL would also be created When the data is post processed the CTL file identifies all the individual PAY files such that they can be automatically processed in sequence to create a single NC data file There are currently three possible variations on the Sphere parametrics these are shown on the parametrics menu as SPHERE2 and SPHERES SPHERE2 Equal Openings with user specified wind angles This parametric is for vessels with equal polar end openings the users specified the number of layer
87. ch and wind angle FIBER TEX FIBER NAME FIBER TYPE FIBER NUM ROVINGS FIBER ROVING WIDTH FIBER MASS PERCENT FIBER VOLUME PERCENT RESIN NAME RESIN TYPE The above parameters relate to the fibre amp resin properties from the materials database that have been saved in the current payout file MASS RESIN The current estimate of the mass of resin used during winding assuming the user has selected the correct material parameters The fibre amount is known the resin is from the specified resin fraction amp resin density Caution this will be the current value and it is cumulative If you have this at the end of the MPF it will be the total If you have after each layer it will be the current value and will increase layer by layer MASS FIBRE The current estimate of the mass of fibre used See MASS RESIN MASS Current wound mass of composite It is equal to MASS FIBRE MASS RESIN ANROI8 The payout file is a set 3D motion coordinate data that is converted into NC motion for a specific winding machine by the post processor The payout file may also contain some ancillary records that direct the post processor to perform some additional action Ancillary records take the format ANRxx where xx is a number any then may have some other data that follows ANRO8 appears with the line ANR O8 previous point was hoop point If the user w
88. chine control NC data in any way The final stage of the CADFIL system is to translate the payout file into winding machine instructions The post processor performs this task See 1 6 1 Post processors can be configured to produce programs for an almost limitless variety of machines The NC part program is an ASCII format file as are all CADFIL data files permitting easy editing The NC file can then be transferred to the NC controller using proprietary file transfer software and the program should then be run in accordance with the filament winding machine manufacturer s instructions 1 1 6 Licence File Expiry Some of the Cadfil licence data is held with the USB Datakey The Licence may have an expiry date after which the software will not function fully You may get one the following messages if the licence has a limited period to run WARNING licence has less than 30 days WARNING licence has less than 15 days Read Help Topic Licence File Expiry this help topic In this case please send and email requesting a licence file update to with the details of your current software version the serial number written on the Datakey and the name of your company and contact details The licence is a small data file that is supplied by email with full instructions of how to apply it 1 1 7 Material Database Cadfil Contains a database of Fibre and Resin Materials For winding program calculation only two parameters are require
89. cumstances leading to the crash should be noted and the error repeated if possible The user can then contact CCL who will investigate the problem 1 8 3 Non fatal errors Cadfil has numerous non fatal error messages these are usually a direct result of user input errors The error message is displayed in a dialogue box and remains there until the user clicks OK The user is then often re prompted for new data for the invalid input or the invalid input is disregarded and control is returned to the appropriate Cadfil menu These error messages have been divided into sections relating to the Cadfil main program Mandrel generation Fibre Path Generation Payout Path Generation and Post Processing for ease of reference 110 Cadfil Help 8 53 V7 63 1 8 4 Cadfil main program errors messages In its normal mode Cadfil uses standard windows graphics and no drivers are required A colour mode of at least 256 colours is required and a resolution of not less than 640x480 though 1024x768 is preferable SOFTWARE SECURITY FAILURE This message is displayed when the software datakey has not found on running the software When the datakey is not found the user cannot access the options on the Cadfil main menu a warning bell being given instead A discussion of datakey problems is included in the section relating to the installation of the CADFIL system 1 8 5 Mandrel generation error messages UNABLE TO WRITE TO MANDREL FILE This indicates that the
90. d the width of the fibre band the band width to determine the path spacing and and the band thickness to calculate the thickness of the winding if required The band width is a function of the fibre type and also of the dispensing system payout head The tension and guide system will affect if the fibre spreads into a wide type or if it bunches up like a rope Based on the band width and the fibre and resin material properties this band thickness can be calculated For this reason the user must add there own bandwidth data based on experience with the winding machine type The material database allows the user to Cadfil Help 8 53 V7 63 a Save fibre and resin material data for future use b Set material data for a particular winding and report this information to the NC program file for traceability and to add operator instructions such as which resin to use and the number and type of rovings to use A description of the material parameter post processor logicals can be found in the section on See 1 6 3 c Calculate band thickness The material data is containing in and external file cadfil_material_data csv found in the Cadfil system folder C Cadfil Cadfilxxx This is a comma separated value CSV file and can be opened and edited in Microsoft Excel or other spread sheet programs The format and layout should not be changed but the user can add or remove entries as required An example of such a CSV file viewed in Excel i
91. d above Each program is a separate standard axisymmetric program with the number of cycles required to complete the layer automatically calculated The wind angles numbers of bands in the layer and the name of the particular PAY file are tabulated on the screen when the Sphere program is invoked If the basic thickness of a filament band was say 0 18mm and a composite 4mm thick is required then 4 2 0 18 11 1 layers are required and the number of band sets would be specified as 11 In practice the actual thickness of the part will vary a little We have found that the composite is often a little thinner at the poles and the lower angle winding programs can be repeated by changing the number of cycles in the NC data to thickness the composite at the ends Each winding program has a number of data points on it and this is the number of points per circuit A value of 20 works well in most applications This is a compromise between accuracy and the amount of data created 87 Cadfil Help 8 53 V7 63 The spherical clearance radius and end shaft clearance radius define a control surface on which the payout points will lie This consists of a sphere intersected with a cylinder the cylinder being bigger than the mandrel shafts s and the sphere being bigger than the mandrel plus the thickness of the winding Thus the values supplied must be bigger than the shaft and mandrel radii When post processing the payout data from the sphere program the u
92. d for user information as follows the user will note that the number of cycles is not a whole number as it is unlikely that the effective bandwidth will divide exactly a whole number of times into the mandrel maximum circumference By default CADFIL rounds the number of cycles to the nearest whole number The other items displayed are the minimum layer thickness and the total length of fibre for one layer assuming one roving If a thickness file was requested The system will now prompt the user as to whether he would like to update the mandrel profile by displaying MANDREL UPDATE REQUIRED Y N If the user answer Y the display will indicate UPDATING MANDREL PLEASE WAIT Following this the system will request the user to input a new mandrel filename for the updated mandrel The See 1 9 8 is then shown This user can select a band pattern by clicking on the line required Band pattern is discussed in detail in a latter section The system requests the user to input the name of the payout file he wishes to save the payout path data to This file has the PAY extension The system then proceeds to the See 1 4 7 1 4 3 Band pattern selection The band pattern is used to control the final laminate structure by ensuring successive repetitions of the designed fibre path circuits are placed in the correct positions relative to each other This usually involves making a small modification to the calculated design path by the progression fact
93. d the mandrel is specified in mm the gear is 1 0 It is strongly recommended that a system of units for the mandrel are adopted and then used constantly This removes the need to change the scaling data in the configuration file once it has been set up correctly In practice all customer use either mm or inch for the mandrel definition OFFSET AX n These values for each axis n 1 to 6 from the machine reference point machine home position or payout origin to the spindle datum The offsets MUST be in machine units and have the CORRECT SIGN They are the values one would use to instruct the machine to move crash the centre of the payout origin the position were the payout eye is attached to the spindle datum point These offsets are constants for the machine but may change when maintenance work is performed on it The spindle datum point is a fixed point on the machine winding axis this usually being located on the head stock or tail stock When the mandrel is located in the machine the position of the mandrel must then be measured from this point Thus the mandrel s position can be defined in the machine co ordinate system vie the Xdatum post process variable See 1 9 20 FEED DEFAULT WIND This is the value of feed rate that is used in the NC subprogram to wind the component 40 Cadfil Help 8 53 V7 63 FEED DEFAULT START This is the value of feed rate that is used in the move to the start position in the NC main program
94. d the programs are smaller to use the Cadfil pipe winding option using the equivalent mandrel radius spar perimeter 2PI and ensuring the radial clearance is greater than the maximum radius of the section 95 Cadfil Help 8 53 V7 63 Low angle winding where the winding paths pass over the mandrel end this is generally required for wind angles less than about 40 degrees 0 degrees being axial The software automatically generates the mandrel geometry See 1 9 18 There are three variants See 1 7 10 4 The Mandrel has a idealised ellipsoidal end dome See 1 7 10 5 The Mandrel has a idealised ellipsoidal end dome with an elliptical end boss and an enhanced clearance surface See 1 7 10 6 Transition joining paths generate a single path program to be created to go from programs of different wind angle and or start position This function is not available at the present time For all of the options a windows dialog like the one below is used the parameters and descriptions vary for each option The common features are described here and further details are given under the links for the specific options 96 Cadfil Help 8 53 V7 63 Spar Winding mandrel from DXF nasi Mandrel Start Cancel Mandrel Finish Xx CALCULATE Help Dome lenath No Dome sections 0 Shaft Radius Write Param s Shaft Length End Plane X Pos 1 Extra Dwell Dist End 1 End Plane x Pos 2 r Payout Clearance Mode Extra Dwell Distance
95. defined very few sections and or few elements per revolution see the sections on mandrel meshing The fibre will now advance with ACTION along the cylindrical section of the mandrel and will turn around on the dome end Once the fibre has turned around the second hoop point has been defined and the path is complete The fibre should always be advanced at least three segments past the point where it is seen to turn as this allows the software to accurately locate the turning point at a later stage If this is not done an error will be given during payout path generation The path can now be saved and the user can exit and proceed to the payout path generation See 1 3 8 1 3 8 Specific diameter opening required This section enables the user to generate a fibre path to give a component which will have a specific diameter opening in one end At an end of a component the fibre turns round and therefore the fibre will be travelling in a hoop direction around the mandrel We can therefore use this property to start the fibre at this position in the hoop direction The user can fix the X position by using the RADIUS option at menu 3 4 The user is prompted for the mandrel radius at the end opening the software the start at the left and of the mandrel putting a marker on the mandrel when the mandrel radius matches the value entered A menu with SELECT THIS POINT YES NO appears If NO is selected the next location on the mandrel is shown
96. diameter opening at one end of the component 3 Are there any features of the mandrel that may give rise to difficulties during the fibre path development The answers to the above questions will determine which is the quickest simplest or most accurate method of developing the fibre path to achieve the desired features This is discussed in later sections See 1 3 4 1 3 4 Winding Trajectories The geometry of the component previously defined in See 1 2 1 determines the stable paths that the user will be able to achieve The main requirement of the fibre path when determining its trajectory is that it should not slip This is accomplished within CADFIL in two ways 17 Cadfil Help 8 53 V7 63 In the first method the fibre path follows a geodesic path this being the shortest distance between two points on the mandrel The limitation of this method of fibre path generation is however that once the initial conditions of start position and start angle have been input the rest of the path is uniquely defined by the geometry of the component Therefore the scope for attaining an optimum winding pattern for mechanical and environmental requirements can be limited The second method of path generation makes use of the frictional effects between fibre resin and mandrel surface to allow the fibre to be deviated away from the geodesic non slip path to a See 1 9 6 non slip path The amount of deviation from the geodesic path is d
97. ding about 8 points per rotation for higher angles is more than adequate however when the user looks at the Cadfil graphics the path will appear not to be smooth If good graphics are required use a small spacing Please note 106 Cadfil Help 8 53 V7 63 that calculate time will be large and the data files and winding programs will be large if the spacing is small End Plane X position amp 2 These values are not used and will be greyed out Dwell Hold radius The machine will move do this distance from the winding axis on the end planes whilst the fibre is wrapped around the mandrel shaft Bandwidth is the actual width of the fibre band to be used This is used to calculate the number of carriage circuits required for a layer and is also used for the graphics of the banding structure End turning length Not used Friction coefficient Mu Not used Wind angles Degrees is the value in degrees that the user requires in the central portion of the wind path i e the total length excluding and turning zones The Low angle option does not have a turning zone as the fibre turns on the mandrel ends thus the wind angle is fully up to the mandrel end Payout clearance and mode This feature is no longer used as the clearance is always from the DXF file as this is the most general and flexible method Mandrel Direction check box If ticked default the program is generated such that the mandrel rotates in the positive direction
98. drel mnd files fundamentally changed If a user tries to read a mandrel file from an older version and error such as invalid mandrel file header will be given It is possible to convert old mandrel data to the latest format using the Convert old mandrel option on the utilities menu The user is prompted for the mandrel name and then the new mandrel name By default the new name is the same as the old name and if this is not changed the old mandrel will be replaced If the mandrel had an Envelope file this will automatically be converted and added into the mandrel file data The envelope is part of the mandrel file post in v5 and later versions If the mandrel had no envelope definition a default definition is created PLEASE CHECK THIS ENVELOPE Note that the format of the FIB and payout files also changed as the mandrel surface is now defined using quadrilateral elements rather than triangular elements There is no conversion facility for fibre path or payout path files These will have to be re created 1 3 Fibre Path Creation 1 3 1 Introduction to fibre path generation This section discusses the Fibre Design section of the CADFIL system It briefly deals with the requirements for the generation of the fibre path initially starting with meshing of the mandrel advice on selection of the fibre start method winding trajectories and the fibre path requirements of the CADFIL system It then goes on to describe example situations
99. e QuickCAD main menu if optionally supplied This allows the winding of non round sections of constant or near constant section The section should not have concave portions as these cannot be wound successfully Click See 1 7 10 1 to return to the main topic Low angle winding where the winding paths pass over the mandrel end this is generally required for wind angles less than about 40 degrees 0 degrees being axial The software automatically generates the mandrel geometry See 1 9 18 There are three variants This variant has a dome end The dome is considered to be elliptical in side or plan elevation blending from the mandrel section shape to the circular shaft The only variable describing the dome geometry is dome length which is the length from the section where the mandrel start to change shape to where it meet the shaft This length is assumed to be the same at each end of the mandrel The windows dialog below show the input parameters The winding progresses along the constant section of the mandrel at a constant wind angle the winding goes around to dome going tangent to a shaft or circular boss than then turns back to traverse the dime to enter the constant section of the mandrel at the correct wind angle for winding the reverse part of the circuit 105 Cadfil Help 8 53 V7 63 Spar Winding mandrel from DXF Mandrel Start 3 Cancel Mandrel Finish X CALCULATE Help Dome length No Dome sections Read Param s
100. e and is useful to determine if there are two acceptable hoop points for create a payout path or to determine the size of the end openings that have been generated The objective is to steer the path across the surface of the mandrel to achieve the wind angles and mandrel coverage required At any stage the user can change the fiction parameters to help steer the path If no friction is set then the path will be geodesic i e it will follow the shortest path across the mandrel surface given the current position and direction of travel Please refer to the examples at in the appendices of this help file See 1 3 11 1 3 11 Fibre Paths Display Options These options determine how the fibre path is displayed in the screen and are accessed from the Display options entry on the See 1 3 10 The options are as follows Not Shown Selecting this option will remove all hidden detail from the view requested The only fibre which is visible on the front of the mandrel will be displayed Change colour Hidden fibre is shown in a different colour Dashed line The colour of the fibre is the same as that on the front of the mandrel but it is drawn in a dashed line default option From C T Line The fibre is rotated around the mandrel until the end point is on the mandrel centre line Only FibEnds Markers are shown for the fibre start and end positions only used for non axisymmetric systems Show as band The user is asked for a band width and
101. e at each end of the mandrel Elliptical Boss Dim A The elliptical boss can be used if it is more sympathetic to the section shape of the mandrel The ellipse has a semi major axis length of Dim A aligned with the X axis from the DXF section The semi minor axis is Elliptical Boss Dim B If required the elliptical boss can be roated relative the DXF X axis by an the Boss rotation angle in degrees if this is more sympathetic to the mandrel cross section shape If DIM A and B are set the same the boss is circular The Envelope vertex defines a 3D clearance around the dome end The clearance surface from the DXF file is linear between the 2 end planes Then it becomes a conical surface with the cone base being the clearance surface on the end plane and the cone vertex being on the winding axis a distance outside the end planes defined by the envelope vertex The vertex distance would normally be longer than the dome length Minimum Arc length around the section is the typical spacing of data points along the path on the mandrel surface the units will be the same as the mandrel units usually mm or inch For reasonably accurate winding about 8 points per rotation for higher angles is more than adequate however when the user looks at the Cadfil graphics the path will appear not to be smooth If good graphics are required use a small spacing Please note that calculate time will be large and the data files and winding programs will be large if the
102. e patches I e the shade is constant over the patch This gives the mandrel a faceted appearance that is more pronounced if the mesh is course Shade Bi linear This option is similar to shade linear except that the light shade intensity is calculated at each node or vertex on the patches and the shading is bi linearly interpolated over the patch On curved surfaces this gives a much more realistic image even if the mesh is very course The rendering process is slower If there are sharp discontinuities in curvature on the mandrel this shading options is give a slight localised anomaly in such locations In this instance the shade linear option perhaps with a denser mesh may be a better options Cull Patches This switches surface culling on or off Culling is the automatic removal for display of all patches whose normal direction is away from the view direction Can be useful for non axisymmetric and RTM work Edges ON OFF Used with shading to draw the patch edges Fill Times Used in RTM work the fill time at nodes can be interrogated by clicking on them Property Display Shades patches according to the current property index non axisymmetric and RTM work only Zbuf Invert Used in shading the Zbuffer can be inverted such that objects to the rear of the view come to the front and visa versa non axisymmetric and RTM work only 1 3 14 Creating a Joining Path This option is selected from the Cadfil Main menu A joining path is used
103. e set but the points were set to 4 then X4 would be assumed to be zero and the program would hoop wind to mandrel position X X Position 1 See above Dwell Deg 1 See Above Loading data from a spreadsheet It may be a requirement that the user wishes to create a multi hoop program where the X positions change in a formulaic way an example of this is a hoop rib on a pipe where each layer steps in position from the last so that rib does not have a sharp edge that the bands would fall off after a few layers of height is added In the way we might have hoop with a series of positions in the series x1 x2 xl inc x2 inc x1 2inc x2 2inc where inc is a fixed value It is possible to prepare that parameter data in a spreadsheet with user created formulas and then export this data to a parameter file the multi hoop can read An example Excel file with instructions within it can be found in the data folder of the Cadfil installation folder The example is called MHt2 xls 1 7 4 Dome Ended Vessel Parametric 1 7 4 1 Dome Ended Vessel Parametric The QuickCad application is for cylinders with dome ends and an end shaft The programs generated are geodesic with equal end openings This is part of the Cadfil Lite Lite package With The Cadfil Lite Plus option non geodesic winding can also be made If this option is available then put a tick in the non geodesic box and then you can specify the opening diameter at the ends
104. e to the current machine position After winding a layer the carriage will have advanced a number of bandwidths If a number of layers are required a single reverse motion is needed to get back to the initial position An example is shown below for a FANUC control syntax varies from machine to machine but the general principles are the same M98 P7001 L19 Sub program Number 7001 is repeated 19 times A 360 00 X 120 00 The band width was 6 mm thus the carriage is moved back 19 1 6mm The 360 degree mandrel rotation is to prevent fibre slippage M98 P7001 L19 Wind a second layer The software automatically creates the first sub program call but the additional calls and intermediate motions must be entered manually In the main program the software calculates the program start position so the machine can automatically move to the start position As the mandrel is not rotationally symmetric the original rotational position of the mandrel is very important The software assumes that the plate is in the horizontal position prior to the program being run Positioning the mandrel in jog mode using a spirit level is the best way of achieving this If winding programs for different wind angles are created the software will create a full NC program for each wind angle It user can edit these programs together manually if these need to be wound continuously Care must be taken to ensure continuity of mandrel rotational position and payout position b
105. ecreasing the clearance but the user must exercise caution when using low clearances as a clash with the mandrel could occur if measurements have not been made accurately 1 6 5 The 3 and 4 axis post processors The post processor asks the user a number of questions these are The name of the payout path PAY file to use The name of the program file PRG to create XDAT See 1 6 13 3 to locate the mandrel in the machine The Payout eye extension length The feed rate calculation method and winding speed The See 1 6 13 7 for the main program if required The NC part program number for the subroutine if required These are explained in more detail where necessary in the following sections In most cases the data is checked for validity and the user is asked to re enter invalid values See 1 6 13 2 1 6 6 The 3 axis large eye post processor This is for machines with the Mandrel carriage and cross feed axes 1 e no eye roll axis Were a payout ring is used and a large band width is required a large payout eye would be used However the movement of the fibres from side to side in the eye can lead to inaccuracies in the winding particularly on end domes where slippage could result The post processor is identical to the See 1 6 1 except the user is requested to enter the Payout Ring Radius This value is then used to correct the payout eye positions for the movement of the fibre in the payout ring 1 6 7 The 5 axis post proce
106. ective action See 1 8 3 and to later exit from the program in the usual manner These are described separately in the following sections 1 8 2 Fatal errors Errors causing the program to terminate should be very rare once the software has been correctly installed They are described here so that the user can take appropriate action if they occur When CADFIL is run an error logging file called CADFIL LOG is created Various messages can be written to this data file these can be viewed using a text editor such as Notepad If CADFIL terminates unexpectedly in a controlled manner there will be a messages of the type below in the CADFIL LOG file STOP 10 PEYEP orSTOP 50 PEYEP TOO MANY POINTS These messages indicate that a set of circumstances within the software has arisen such that the software would be liable to terminate in an uncontrolled manner or to corrupt data within the memory If such an error occurs first try to repeat the error again if the error is repeatable then it will be much easier to isolate the cause of the problem If the user wishes the problem to be investigated then the best way to proceed is to contact CCL directly The software may terminate unexpectedly writing no error messages to the CADFIL LOG file This will be due to some circumstance that was unforeseen by the authors of the software A message generated by Windows or the software compiler may be written to the screen prior to the system crashing The cir
107. either due to the mandrel geometry or due to the application of friction In this latter case the hoop point is not exactly defined and Cadfil uses various mathematical techniques to establish the exact position of the hoop point to ensure accuracy in the fibre track when it is reflected For these methods to work correctly there must be at least three fibre points to each side of the point where the fibre is seen to turn on the computer screen This error message is caused because the fibre was 116 Cadfil Help 8 53 V7 63 started very close to hoop and then turns around within a couple of steps Hence the hoop position cannot be fixed accurately In this circumstance to avoid this error the user would be better to start the fibre position exactly where required using the hoop facility for the start angle LAST HOOP POINT TOO CLOSE TO END OF PATH GENERATE THREE FIBRE SEGMENTS PAST THE HOOP POINT This error is for similar reasons to that described above except that the fibre path needs to be advanced three or so elements further The simplest solution is to return to the fibre path generation section retrieve that old fibre path and the to advance three or so steps and then to save it again The payout path will then be able to be created in the normal manner MATERIAL FILE ERROR INTERNAL DEFAULTS USED This message is given if the file material cnf is not found or there is an error reading it a set of default properties are assumed These wil
108. end of the mandrel x j To start away from the chuck and then initially a zone Turi SH wind towards it use a aste aste w Start Position Wind Length i negative Total Length of Winding wind length in the PIPE WINDING GEOMETRY Start near chuck lower diagram For Hoop winding each repeat layer is one traverse of the carriage If the repeats are an odd number then the next helical layer will MACHINE DATUM chuck face NU Mandrel Radius k pea GE ee A Sames Turn zone Turn zond automatically swap ends of Waste 2 Waste 2 CCT a T E ae i the mandrel to start This Negative Wind Length p ensures that the winding is PIPE WINDING GEOMETRY Start away from chuck always continuous 1 7 2 2 Pipe Winding Parameters Pipe winding is the most common form of filament winding and programs can be undertaken using the standard Cadfil Axsym software The QuickCad Pipe winding options quickly generates winding programs and Pay files for visualisation based on user specified parameters The pipe winding produced by this program is a double layer winding along the mandrel with a small dwell at each end to allow for a repeatable band pattern This parametric turns the fibre on the cylindrical portion allowing for simple extraction without having to cut the mandrel ends thus it is only suitable for wind angles gt 40 degrees for lower an
109. envelope is a surface that is clear of the mandrel surface on which the machine will run without hitting the mandrel 2 Create a template winding path by steering it across the mandrel surface using friction See the topic See 1 7 7 2 3 Expand the template path if required using the symmetry tools as the T has 2 distinct symmetry planes 4 Replicated paths parallel to the original path separated by a distance that is the bandwidth of the fibres T11 Cadfil Help 8 53 V7 63 5 Process the paths on the mandrel surface to create the 3D machine path payout path on the clearance envelope surfaces 6 Post Process the payout to create instructions for the winding machine 8 It is also possible to generate standard pipe winding programs for the cross piece This can be modified and attached to the T mandrel using a specific T option T Winding T Mandrel Generate Cancel Make Template Path Reflect Path X 0 Reflect Path Y 0 Help Parallel Path Convert Pipe Payfile T mandrel Creation From the T Winding options pick the T Mandrel generate Button The figure below shows the T mandrel and envelope dimensions the actual dimension values in mm or inch are entered in a windows dialog 78 Cadfil Help 8 53 V7 63 EB TEE MANDREL amp ENVELOPE DIMENSION PARAMETERS TEE Mandrel Generator I 2 Axis Mode M Non Geodesic F Joining Path Cylinder Diameter MD o 000000 Cance
110. ependent upon the friction coefficient this being dependent upon the mandrel finish fibre and resin type etc and also upon the geometry of the component A higher local curvature will increase the normal reaction to the component surface this in turn increases the frictional forces available to sustain the fibre on the required path and hence the fibre path will deviate faster The CADFIL system can make use of both of these methods whilst a fibre path is being generated the operator deciding upon the amount of friction to be applied and when to use it See 1 3 5 1 3 5 CADFIL Fibre Path Requirements Since the components that this system deals with are axisymmetric CADFIL only requires the user to develop one half of a complete fibre circuit between two hoop position as shown in the diagram below The hoop positions are the locations where the fibre path turns around The return half of the fibre circuit is automatically generated in the payout path section 18 Cadfil Help 8 53 V7 63 Cadfil Graphics Window Patel Ea FOI HAL NOAS HARITA MERR tid Hoop Point In order that the system can accurately locate the hoop points at either end of the fibre path the user is required to generate a minimum of three points following the hoop position When starting the path unless the user commenced with a hoop direction winding 90 it will also be necessary to have a few points prior to the initial hoop point The f
111. er speed and can be used to optimise winding time When graphics of speed are displayed these are as a proportion of the maximum speed for the axis i e 0 5 50 maximum speed example uses deg min and mm min set all 6 axes even if machine does not have them SMAX SPEED AX 1 60000 SMAX SPEED AX 2 60000 SMAX SPEED AX 3 60000 SMAX SPEED AX 4 40000 SMAX SPEED AX 5 30000 SMAX SPEED AX 6 MAX ACCEL AX n This can set acceleration values for each axis which can help to create a smoother faster winding program For this option to be active in the post processor the option ACCEL_DISABLED 0 must be set this is NOT the default state If ACCEL_DISABLED 0 is set there is a further option ACCEL_CALC_OFF this sets the initial default state for the acceleration check box on the feed rate dialog box during post proces the acceleration option is default on used if ACCEL_CALC_OFF 0 is set This last set can be over ridden by the user each time the post processor is used example of axis acceleration values in mm min mm or deg min min example assuming machine can go from 0 to max speed in 1 15 mins 4 seconds thus accel vmax 15 SMAX ACCEL AX 1 900000 SMAX ACCEL AX 2 900000 SMAX ACCEL AX 3 900000 SMAX ACCEL AX 4 900000 SMAX ACCEL AX 5 900000 SMAX ACCEL AX 6 41 Cadfil Help 8 53 V7 63 A X 3 ROTN OFFSET Machines with a yaw axis
112. erations check box is ticked If the velocity for the next motion cannot be reached within the time length of that line then the time for that line will be increased i e the machine is slowed such that the maximum acceleration for the axis with the problem is respected The acceleration functions are in an experimental state at version 7 27 and the effectiveness is dependant upon the setup and configuration of the winding machines motion NC controller The default velocity and acceleration limits are set in the See 1 6 2 sm file described in another section The calculation mode options are as follows 0 Only specify a feed rates at the start of the NC main and NC sub programs The feed value used in the main program is the start feed from the SM file The feed rate in the sub program is specified by the user but the default is the start feed 1 Calculate feed rates for each NC block such the mandrels rotational speed remains constant maintains a constant feed rate on the A axis 2 Maintain a constant total feed rate on the A and X axes 3 Maintain a constant total feed rate on the A X and Y axes 4 Maintain a constant fibre speed not yet implemented In the post processor configuration file SM file the variable FEED DEFAULT MODE can be set If FEED DEFAULT MODE is set then on the feed rate dialog option 2 above will be pre set Other feed rate variables that can be pre set are FEED MA X
113. esin and the surface of the mandrel The user then develops the fibre path using friction when necessary until the path s completion by the generation of See 1 9 4 within the path The fibre path is then saved and the fibre design section exited The payout path section See 1 4 1 on the Cadfil main menu reads the fibre path data file and calculates the machine positions relative to the mandrel Fibre and resin data and other necessary parameters are given at this stage to determine the number of fibre cycles required to cover the component The amount of fibre required is given and a graph showing the composite thickness on the mandrel is displayed A data file containing machine co ordinate points relative to mandrel is written for use by the post processor If required this payout path data can be graphically viewed to show the machine positions the band structure or to animate the winding Cadfil Help 8 53 V7 63 It is possible to use a mandrel to create a number of fibre path and then payout paths for different wind angles or areas of mandrel coverage To wind these paths as automatic sequence on the machine See 1 3 14 need to be created to connect the end of one winding program to the start of the next Having created a series of payout files and joining payout files these are combined in a See 1 5 1 The post processor can use the control file to generate a complete winding program foe all layers without having to edit the ma
114. esktop shortcut for Cadfil STEP 2 Install drivers Cadfil uses a security device called a Datakey This is a See 2 1 USB port device See 2 3 parallel port devices are not supported after Cadfil version 7 25 Cadfil copies a driver file to the C CadfilNcadfil7xx The driver install program is called DK3win exe A shortcut in the Cadfil programs group on the start menu can be used to run this install Please note that Cadfil Install files downloaded from do not usually include the drivers to keep the file size smaller Driver installation is not required if the user is installing an updated version of Cadfil Drivers can be downloaded from the web page STEP 3 Attach Datakey Attach the USB datakey The first time a USB key is used you may get the message that Windows has found new hardware and is loading drivers please wait for this to complete This message may also occur if you plug into a USB port that has not been used for the datakey before Cadfil Help 8 53 V7 63 STEP 4 Apply a licence file You should have been sent usually by email a small file usually called lic dat This is required when you run Cadfil for the first time after an install Place this file in a convenient location on the PC for example on the desktop You can now run Cadfil my clicking the Cadfil7 icon on the desktop or in the start menu Programs Cadfil7 group Problem Solving You may find that most of the menu options are greyed out
115. essor is to convert the payout PAY file into instructions Numerical Control data for the filament winding machine FWM in order that it may reproduce the designed fibre path on the surface of the mandrel The NC data is produced in the form of a data file that can subsequently be transferred to the winding machine The format of this file is dependent on the type of FWM The naming convention for the machine axes used throughout the post processing sections is as follows The linear Cartesian axes are AX4 AX5 AX6 the rotational axes being AX1 AX2 AX3 AX lis the mandrel rotation about AX4 direction AX2is the payout eye rotation about AX5 direction eye roll AX3is thepayout eyes rotation about AX6 direction eye yaw AX4Carriage travel i e along the mandrel AX5Cross feed travel Primary axis for radial motion towards and away from the mandrel AX6Vertical travel a right angles to AX4 and and AX5 though not necessarily vertical The axis names on any particular machine will be different to those used here this being dependent on the controller s configuration The post processor is configured for the actual axis names on the machine The actual names are set by the LAB AX n settings in the machine configuration SM file CADFIL uses a right handed set RHS throughout the AX4 direction is fixed by the carriage axis direction on the machine AX5 is defined as being in an horizontal plane perpendicular to the AX5 axis the p
116. eters The SPAR winding software is found on the QuickCAD main menu if optionally supplied This allows the winding of non round sections of constant or near constant section The section should not have concave portions as these cannot be wound successfully High angle winding typically 40 90 degrees is where the end are not over wound and there is a turning length at each end of the mandrel then Ingth of which is controlled by the friction parameter Generally if the wind angle is less than 40 degrees the turning length which may be scrap material tend to become impracticably long Note that for hoop winding it is quicker and simpler and the programs are smaller to use the Cadfil pipe winding option using the equivalent mandrel radius spar perimeter 2PI and ensuring the radial clearance is greater than the maximum radius of the section Click See 1 7 10 1 to return to the main topic The windows dialog below is used 99 Cadfil Help 8 53 V7 63 Spar Winding mandrel from DXF et Sam Mandrel Start x foo ooo Cancel Mandrel Finish x eeso o Dome length po 8 No Dome sections ie Shaft Radius oo Write Param s Shaft Lenath oo OOSC Minimum arc length around Section 0 End Plane X Pos 1 Bo Extra Dwell Dist End 1 wooo o End Plane x Pos 2 74300 Payout Clearance Mode Extra Dwell Distance End 2 booo e Enyelope from DYF Dwell Hold radius Bon t s Peed nei Band Width M lt lt y End Turning Length 200 Wind Angle
117. etween programs 93 Cadfil Help 8 53 V7 63 When running NC programs for the first time the user should ensure that he is in a position to stop the machine quickly as minor errors in machine setup can lead to damage to the machine of mandrel if a clash results See 1 7 9 5 1 7 9 5 Plate Hoop winding When the user specifies a wind angle of 90 degrees or a wind angle greater than Tan PHITE BWID Then the format of the winding program will be slightly different As bandwidth is generally quite small relative to the length to be wound there would be a large number of mandrel rotations for one carriage circuit The NC data would thus be very large and perhaps too big for the memory of the winding machine The program is such the for every rotation of the mandrel the carriage advances band width the cross feed moves during this cycle however The software created two payout files and the user is asked to provide a name of the second set of FIB and PAY files At the post process stage the user must process both payout files that have been created thus creating two sets of PRG files The first NC program will have an NC sub routine that is called a number of times to form the outward part of the carriage circuit and to provide a full half layer the second set of NC data will have a second NC subroutine that is called a number of times to give the return part of the carriage circuit E g for a FANUC control the first program
118. file SP EPAPARA Enu ick the don I Beete aaa CHM HHepathle V120T02 pay at eae ise E asthe picture to ate the payout path and save as apliek finish and save the combined file V120 ctl 57 The last step will be to Pick 4 axis post process from the NC Post Process menu and pick the V120 CTL s to post process with V120 prg as the output NC file There are a number of post processor configuration specific options which are described in the help file and finally we have the completed NC data for winding the CNG tank
119. gles so the user can adjust for this here if required Machine feed rate is the winding speed for each layer The default value is from the machine configuration file The winding machine supplier should assist in the setup of this file Circuits per layer is a calculated value of how many circuit the winding program makes to complete one full layer For hoop winding this is always 1 Band pattern Number is the number of starts and is explained on following pages of this document There is no pattern as such for hoop winding Dwell rotation is additional mandrel rotation at the ends to make a particular band pattern work correctly The amount of dwell can be minimised by keeping the default band pattern selection mode mode 0 Wind time is the layer wind time a total is shown at the bottom Times are calculated at NC generate stage Waste length is the length out of the total wind length used for turning where the wind angle is not true Half of this amount will be at each end The Pull down menu for band pattern and feed rate mode selection are shown below There are three options for band pattern the user can choose that a pattern of 1 is automatically selected for each layer or the pattern with the smallest dwell is selected Viren the date hes been Wind The NC data Start position explained 64 Cadfil Help 8 53 V7 63 MACHINE DATUM The Start position can be at chuck face NU Mandrel Radius x Y ys either
120. gles the turning zone becomes very long and hence there is much waste material For lower angles the dome ended See 1 7 4 1 or the full Cadfil Axsym system should be used The user specified parameters are Cylinder Radius This is the radius of the cylindrical mandrel Clearance Radius This is the distance of the fibre dispensing point from the axis of the cylinder This MUST be bigger than the mandrel radius Start X Position The start X position i e postion along the mandrel can be set The actual carriage position in machine co ordinates can be modifed by the See 1 6 13 3 and See 1 6 13 9 during post processing Total Length of Winding 65 Cadfil Help 8 53 V7 63 This is the length of the winding band centre to band centre This can be positive of negative as the winding will be from the Xstart position to Xstart position Winding length The overall extend of the winding will be 1 2 a bandwidth more at each end as the band centre position is programmed Friction Coefficient The friction coefficient Mu is used to provide a none slip fibre turnaround at the mandrel ends The fibre is progressively turned around at the outer end of the parallel length The higher the value the shorter then length of the turn around will be Values in the range 0 01 to 0 25 are usually used but this will vary with materials being used It may not be possible to turn the fibre around if the friction coefficient is too small or the paralle
121. h end dome The end opeing can then also deviate from the normal geodesic end opening that occurs from specifying the wind angle on the cylinder 1 7 5 Vessel With Encaps Beta Version 1 7 5 1 Vessel With Endcaps This part of the software is pre release level beta and the help topic has not fully complete Different end caps can be specified for each end of the mandrel from the pull down list box the end caps have parameters R1 R2 amp R3 To see an explaining End cap types follow the link See 2 5 The clearance parameters are explained in the following diagram Please note that having C2 gt half the with of the payout head is advisable to avoid collision with the end cap The user also needs to specify the fibre band width W and Winding angle A For unequal end openings the non geodesic box can be ticked and then the openings at each end can be specified Please note that these are for the centre line of the band so an end opening radius 0 5 W larger than required should be used There are some known issues problems with the non geodesic winding on this option The process process is 1 Enter the data parameters 2 save the parameters and give them a file name lt name gt par 13 Cadfil Help 8 53 V7 63 3 Calculate the program with the Calculate button 4 Exit the dialog and review the payout data in the payout viewing option that is automatically run The payout 5 Review the messages in the Cadf
122. he ends can become large so the range of practical elbow geometries that can be wound is significantly reduced The friction coefficient Mu is used to provide a none slip fibre turnaround at the mandrel ends The fibre is progressively turned around at the outer end of the parallel length The higher the value the shorter then length of the turn around will be Values in the range 0 01 to 0 25 are usually used but this will vary with materials being used It may not be possible to turn the fibre around if the friction coefficient is too small or the parallel length of the elbow is too short The program will issue an error if this condition exists Wind angle degrees Alpha this is the helix angle of the fibres on the mandrel surface with respect the winding axis This angle is maintained at all locations except the turning zone at the mandrel ends Because of geometric constraints of fibre bridging across the inside of the elbow or fibre slippage it is not possible to use low angles The program does not permit angles less than 45 degrees though if the bend radius is tight the minimum wind angle that can be used in practice may be higher than this 1 7 7 Tee Winding 1 7 7 1 Tees Winding Overview amp Mandrel Cadfil has a number of specific modules for Windings Tee these can be found on the T Winding Option on the QuickCAD menu The are a numbers of stages 1 Generate the mandrel surface definition and an envelope definition The
123. he mandrel for generating the payout path If the user wished to view the hoop winding band structure in the payout path viewing options then use a small value say 12 degrees for creating NC data for winding a large value say 175 degrees is best This value must be less than 180 degrees Mandrel Direction 1 1 Set this to 1 for positive mandrel rotation and 1 for negative mandrel rotation Number Of X Positions This is the number of X positions and is a whole number between 2 and 8 For example is three is specified the user is expected to specify X position 1 X1 and dwell angle 1 DW 1 as well as X2 DW2 and x3 DW3 so in this example the machine would move to the first mandrel position and the mandrel will rotate DW1 degrees the machine will then hoop wind on a helical lead equal to the bandwidth to the second position X2 and will then dwell for DW2 degrees finally the machine will then hoop wind to position X3 and dwell for DW3 degrees If in this example X3 X1 we would have the sample program as the See 1 7 3 1 with a winding length of X2 X1 70 Cadfil Help 8 53 V7 63 The number of positions is currently 20 If more than 20 are required used more than one multi hoop programs to do this WARNING If the values of the number of positions MUST mach the number specified if the user specified X1 X2 X3 amp X4 but only set the number of points to 3 then X4 and dwell 4 would be ignored and not saved If only X1 X2 amp X3 wer
124. he menu options are greyed out and cannot be used A security error message may be given and you could be directed to this help file if you chose to be To fix this you need to go to the utilities menu and select the Apply New Licence file option You will then need to browse in the file open box to find the licence file you saved earlier Having read the licence file you can then see the Cadfil the Message Licence Update Succesful in the Cadfil Text window you may need to scroll down this window to read the messages If you get an error please note the error number and contact CCL It may be that you need an updated licence file Security error messages will be of the format Security failure code xxx View Help Error codes meanings are shown below It is suggested that you a Check the Datakey is plugged into the PC and try to run Cadfil again After plugging in a key wait a few seconds for windows to find it b Re install the driver files see step 2 and try again c Contact CCL 132 Cadfil Help 8 53 V7 63 For other codes you may just need to apply the latest licence file as described above If the error persists please contact CCL Contact details are at the start of this help file and can also be found on the Cadfil About option Cadfil Run Time Licence code errors 1 No DK3 driver 2 No DK3 found 5 16 17 Corrupt DK3 datakey data 6 7 8 18 Licence expired 9 DK3 found but not recognised no
125. he properties are the current properties that apply to this selection The material data is fixed in the database the only one that the user can override change on this screen is the roving width band width On selecting OK the following screen is shown Winding Material Fibre Name Type Toray T400HB 6000 Carbon Resin Name Type Sample Epoxy Epoxy Number of Rovings volume Fraction x 50 0000 Roving Width mm 3 5000 p Band Properties eee Fibre Tex g km 396 0000 Fibre Density g cm3 1 8000 Band Width mm Resin Density g cm3 1 1000 Band Thickness mm Units Metric mm OK Cancel 11 Cadfil Help 8 53 V7 63 This displays the current selection of materials and the user can set the number of rovings being used for the current winding It is also possible to set the expect finre volume fraction or fibre mass fraction for the final composite that is expected The calculate button shown the current band width roving width x Number of rovings and the expected can thickness given the specified material properties and fibre fraction The calculate is also automatically performed when the screen is exited with the OK option Band Width and Band thickness are the only parameters required to calculate a winding program 1 2 Mandrel Creation 1 2 1 Overview of Mandrel and Envelope Creation For rotationally symmetric shapes the first stage in generating winding programs is to create a mandrel fi
126. ibed in a later section See 1 3 14 1 3 7 Specific wind angle required An example of a situation where a specific wind angle is required is discussed below See 1 9 11 or some other shape of reducing diameter The user wishes to generate 30 degree winding on the cylinder but is not concerned about the end opening diameters at the cone end Referring to the previous section on starting the fibre path the user can use the CURSOR option to approximately fix the path start location on the cylindrical section of the mandrel near 20 Cadfil Help 8 53 V7 63 the cone end The start angle can then be specified using the ANGLE option In this case as we wish to pass over the cone end first we specify and angle of 150 180 30 150 refer See 1 9 5 The fibre can then be advanced one segment at a time menu using the ACTION option Setting STEP to a larger number 5 or 10 for example will speed things up As the fibre advances down the cone the winding angle displayed will be seen to change and eventually the fibre will turn around Thus the first hoop point has been fixed This position will later be the start or tie on position on the winding machine The fibre angle will then increase and then due to geodesic theory when the path is back on the cylinder the wind angle will be 30 degrees There may be a small angle change e g 0 1 degrees due to the fact that numerical methods are used Larger changes may be seen if the mandrel is poorly
127. ibre turns before reaching the mandrel end or it may be necessary to disregard the fibre path and select a new start position or angle and create a new fibre path MEMORY FULL ERROR This message occurs during fibre generation when several hundred fibre points have been created indicating that there is no room in the computers memory for further data It is unlikely that this will prove to be a practical limitation for he user bearing in mind that it is only necessary to generate the fibre between two hoop points The only practical situation where this could occur is when winding near hoop along a long cylinder This problem could be reduced by using less elements on the mandrel but for simple hoop winding on a cylinder is it much easier to create an NC program by hand as it need only contain two or three lines of NC data that can be simply calculated UNABLE TO READ FIBRE DATA This message is displayed when the software is trying to read a fibre path file and either cannot find the file specified in the current directory or cannot read the file because the data has been corrupted It will often be the case that the user has supplied the file name incorrectly and thus the solution is to supply the correct name A common cause of corruption in the fibre file would be if it has been edited and the data structure is no longer correct The structure of the fibre path file can be found in the appropriate appendix 1 8 7 Payout path error messages
128. il Help 8 53 V7 63 thus if these were 10 degrees 100mm and 50mm the distance would be y 10 100 50 112 25 If the feed rate was 1000 mm min then the time taken for the motion is speed distance time gt gt time distance speed 112 25 1000 0 1 1minutes 6 7 seconds if there was also and eye rotation of 15 degrees then distance V 10 100 50 15 113 24 so if we wanted a combined feed rate of 1000mm min for the first 3 axes we would need to actually specify a feed rate of speed distance time 113 24 0 11 1009mm min This methodology is applied for options 1 2 and 3 to specify a combined feed on mandrel mandrel carriage or mandrel carriage cross feed For option 4 the winding speed is the rate at which the fibre is deposited on the mandrel Please note that the machine will have a maximum feed rate value that can be used This should be set in the SM file If this value is exceeded during feed rate calculations the feed rate will be set to this maximum value The option and speed selected will effect the smoothness of machine motion and the total time required to wind the part An indication of total winding time is given in the NC data Starting speed This is the speed used at the start of the program to move to the initial tie on start position This is often a slow value The default value is set in the SM file See 1 6 13 7 1 6 13 6 Axis Speed Summary Dialog When the pos
129. il text window this shows errors and other important information 6 Exit payout viewing and post process the lt name gt pay file 1 7 6 Elbow Winding 1 7 6 1 Elbow parametrics This generates full coverage winding programs for elbow pipe bend components See 1 9 14 The elbow parametric can be invoked if supplied from the Cadfil parametrics menu described elsewhere in this manual The user enters a series of data parameters which are saved as a lt filename gt PAR text file and example file EL1 PAR is supplied with the software in the EXAMPLES directory The program automatically creates a lt filename gt MND and lt filename gt PAY when run These can then be viewed using the payout options or post processed using the CADFIL post process options The basic data parameters are as follows Elbow Parametric Mandrel radius R The external radius of the pipe Centre Line bend Radius Rc Bend angle degrees A Elbows are commonly 45 60 amp 90 degrees Parallel length both ends L The acual length of the cylinder on the mandrel can be longer this is the length that will actually be covered by the winding program Wind axis offset distance Yoff Note the direction of the Y axis in the diagram Winding axis offset is normally thus a negative value Points per rotation N This determine the amount of points in the final program a value of 12 to 16 is normally good Band width Bw Free fibre length
130. is the direction the mandrel rotates a value of 1 default give positive mandrel rotation 1 gives negative mandrel rotation Each layer can be repeated a Wind angle calculated from number of times For hoop 1 and width automatically The machine speed can be layer is a single machine for hoop winding changed for each layer A default traverse uses 2 for a double value is applied but can be over ridden layer that comes back Waste Layer Number ateachEnd Minutes Length 5 Number of 9 Repeats pE 138 228 515 8 1 0 oo 72 ezi peers e ee E Cover factor is 100 by default but the user can over ride it here This can be used to adjust the band width If a cover factor Automatically generated data 200 is used the programmed bandwidth when the Calculate button is will halve so the bands will overlap For a clicked Layer Sequence cover factor of 50 the winding will have Numbers Up to 10 gaps During winding the bandwidth may be layers per form can be slightly different for different wind angles so entered the user can adjust here Layer Data Explained The previous picture shows the data layout for each layers New layers can be made using the add or insert buttons or deleted with the delete layer button The data items are described below Hoop Helical Buttons Each layer is either hoop or helical If hoop is selected the wind angle will be calcu
131. ishes an action can be associated with this event for example every time a hoop turning point is reached by flipping a fixed stop payout eye rotation that can be found on some older machines that do not have a programmable payout eye 46 Cadfil Help 8 53 V7 63 rotation This works as follows set the output for the NC machine with the SM file variable ANRO8_HOOP_ACTION_TXT1 For example ANRO8_HOOP_ACTION_TXT1 M88 outputs the code M88 which could have been set on the CNC to perform a specific action In the SM file we our then add ANR08 to the blocks BLOCK SPF START BLOCK SPF MIDDLE and BLOCK SPF END that are used for sub program motion data formats Note we now have ANRO8_ HOOP_ACTION_TXT1 and ANR08_HOOP_ACTION_TXT2 which are used alternately to allow for the set and unset code to be different For example BLOCK SPF START LAB AX 1 AX INC 1 LAB AX 4 AX INC 4 ANR08 Each time the ANRO8 appears in the payout file at the turning points the codes ANRO8 would be replaced by M88 and at all other times it would be replaced by null text i e removed If ANRO8_HOOP_ACTION_TXT1 or 2 is not set in the SM file then there will be no output as it will by default ne set to a null string 1 6 4 The 2 axis post processor The 2 axis system is best suited to the winding of cylinders though can be used for other components with care The operation of the 2 axis post processor is exactly as for
132. k of Crescent Consultants Ltd Email sales cadfil com Web http www cadfil com CNG Tank example Page of 22 Slide Show gt gt Haage E E lt 7 2 gt Es Es Fal Fal SIE Se 2 10 notes_flag gif Notes gt gt HHAH Ket 4 gt gt 2 EHEHEH ik Outline 8 amp 8 gt gt gt EXJEJEARARIR Kk Click to edit Master text styles Second level Third level Fourth level Fifth level ooter gt 9 44 Clida 1 2 11 Slide 1 Email sales cadfil com Web http www cadfil com CNG Tank example Page 1 of 22 149 Cadfil Help 8 53 V7 63 2 12 Slide 1 Email sales cadfil com Tutorial littp Quaiedarn ccDene WessebW ithokimadCaps Vessel With End caps from QuickCad Menu 2 139 Shidecdmetry is pba hea ENERE as RrBfrsased KBibTARgas CNG cylinder Emai end CARS Geet coupprisgyL Show ara Ea AAN Rm en D end V120H01 Machin caps can be different but are the am Pon aP ann hoop to 4 elical v120T02 Directii A a very good torispherical poet eral Tene ka as the ateo shape V120P03 can usually be made Elliptical d spherical end caps can seat be used 21 ie bi ida ypa and Tejagstariebis not enantipiereramiag asas onea senleedisatgaged to IsHPiRsP EOWA Hated endts of thie Wafer US ORERE ed uih Bab 7860 Ah BANE EMG He hae rian andrantlhave geodesic winding non Emailwell sasa rsdilediave aViasss diahiecewwt SOfinemt GNGTskenenaled 7021 athe REft end 21 Clicking the calculate button starts the p Bef
133. king normal to the mandrel X Z plane X END This is an Y Z view looking onto the x end of the mandrel X END This is an Y Z view looking onto the x end of the mandrel ISO View This gives a mandrel isometric view with the mandrel axis running across the screen from bottom left to top right USER This permits the user to define a view direction The system requests 3 angles to be entered in degrees these being the rotation of the component about its axes The first value prompted for is the component s rotation about the X axis The second value requested is the rotation of the component about its new Y axis this being modified 26 Cadfil Help 8 53 V7 63 due to its rotation about X The final value requested is the required rotation about its new Z axis This again being modified from its original orientation by a rotation about X and a secondary rotation about its new Y Zoom Window This allows the user to zoom in on a particular area of interest and is particularly useful with long thin mandrels as it can be difficult to see details clearly when the mandrel is fitted to the full screen On selecting ZOOM the user must use the MOUSE to define the area of the current view that is to be fitted to the screen The user is prompted to select two cursor positions after entering the first point a rubber band box is drawn from this location to the current cursor position indicating the area that will be selected when the second cursor p
134. l Blend Radius MBR fo ooo000 Read Param s CrossPiece Cylinder LenMCPL fo oooo00 Branch Cylinder Length MBCL fo oooo00 Wite Params Envelope CrossPiece Len EC fo 000000 CALCULATE Envelope Branch Len EB fo 000000 Envelope Cylinder Dia ED fo oooo00 Help Bandwidth BWwID fo 000000 Envel Branch Otr Diam EOD 0 000000 79 Cadfil Help 8 53 V7 63 Cylinder Diameter MD The cross piece pipe and branch pipes are the same diameter Blend Radius MBR This is the surface blend radius between cross piece and branch pipes Typical values are between 0 25MD and 0 5MD Cross Piece Cylinder length MCPL This is the length outside the blend area at each end see diagram The Cross piece total length is 2 MCPL 2 MBR MD Branch Cylinder length MBCL This is the length of the branch above the blend area see diagram Envelope Cross piece length EC This is for the machine clearance refer to the diagram If the position of the machine wants to be further away in length from the mandrel centre the machine will then move on a circular plane at the end of the envelope Caution is required as shaft collision could occur This can be checked in the payout viewing options or in the post processor output EC must be greater than MCPL MBR MD 2 to be clear of the end of the mandrel typically add a mandrel diameter Envelope Branch length EB This is for the machine clearance refer to the diagram If the position of the machine wan
135. l be displayed on the screen for the user to select or to enter new values in the usual manner Information on how Cadfil tries to locate this file can be found in appendix a section 4 and the format of this file can be found in appendix B ERROR READING THICKNESS FILE UNABLE TO OPEN THICKNESS FILE Refer to Mandrel generation errors ERROR WRITING THICKNESS FILE This error will usually be generated when the disk is full The user will need to exit from the program and create more disk space 1 8 8 Post processor error messages POST PROCESSOR LICENSE NUMBER nnnnnn NOT CONFIGURED This error occurs when that datakey has not been found Possible reasons for this error are discussed in the sections relating to the software installation ERROR READING MANDREL DATA This error is generated when there is a data format error in the mandrel file that is being read or that the end of the file has been reached unexpectedly The format of the mandrel file can be found in the appropriate MANDREL FILE NOT FOUND 117 Cadfil Help 8 53 V7 63 This error occurs when the mandrel file name that has been read from the payout file cannot be found in the current directory ERROR OPENING MANDREL FILE Unexpected error when opening the mandrel file contact CCL ERROR OPENING PAYOUT FILE Unexpected error when opening the payout path file contact CCL ERROR OPENING PROGRAM FILE This error message indicates that there was an error opening the file f
136. l length of the elbow is too short The program will issue an error if this condition exists Fibre Band Width The width of the fibre band used to determine the winding angle such that the cylinder is fully covered by a calculated number of carriage circuits Mandrel Direction 1 1 Set this to 1 for positive mandrel rotation and 1 for negative mandrel rotation 1 7 2 3 Tapered Pipes Help File additional information This software option is similar to the QickCAD pipe winding software and works for tapered pipes where the taper slope is generally less than 1 20 Constant angle winding on higher tapers may not be possible due to fibre slippage This option is entered from the QuickCad menu by selecting the taper pipe option The data entry form is shown below 66 Cadfil Help 8 53 V7 63 QuickCad Tapered Pipe Winding 2 Aus Model r r Mandre End1 Position 200 0000 Cancel Mandre Radius Endl fi 00 0000 Read Param s Mandrel End Position a000 000 Mondrel Radius End 50 00000 cos Cleoronce Radius fi 50 0000 CALCULATE Mandre Surface Clearance dist f poe f Start Position Along Mandre 400 0000 Help Total Length Of Winding 2500 000 Wind Angle Degrees 0 90 3s 60000 Friction Coefficient e g 02 fo 2000000 Fibre Band Width 30 0000 En eres recess Angular Point Spacing Deg fi 2 00000 Peale Lables sind Mandre l Direction 1 1 1 Mandre Radius End NEn Mandrel Radius End2 chuck bca TAPE
137. lated to give a helical lead of one band with If you wish the Bands to overlap or gap for a hoop winding use the cover factor parameter Helical winding creates a layer at the wind angle specified by the user Number of repeats allow the layer to be repeated a number of times For example with a helical winding setting 3 gives 3 layers It is not good to set the number of repeats to high numbers as the mandrel radius increases with each layer and the wind angle will thus change slightly with each repeat layer Eventually gaps will start to appear between the bands This effect is more pronounced if the mandrel has a small diameter as the change in thickness with each layer will be proportionately more For hoop winding 63 Cadfil Help 8 53 V7 63 each layer is a single traverse if an odd number is specified i e 1 3 5 the next layer will start at the other end of the winding length Wind angle is the helical angle in degrees 0 is axial 90 is circumferential hoop For simple pipe winding no end caps angles below 40 degrees are not advisable as the turning length waste increased dramatically Cover factor is 100 by default but the user can over ride it This can be used to adjust the band width If a cover factor of 200 is used the programmed bandwidth will halve so the bands will overlap For a cover factor of 50 the winding will have gaps During winding the bandwidth may be slightly different for different wind an
138. le defining the shape to be wound At the same time the user can create a mandrel envelope This is described in the section entitled See 1 2 2 The mandrel and envelope data are saved in a text file with the mnd file name extension A mandrel definition consists of X R data co ordinates defining the surface The user needs to define sufficient points to have a reasonable representation of the curvature of the mandrel profile There are a few points to note Fine detail such as small internal concave blend radii are not required and indeed can prove counter productive It is usual to divide the mandrel such that for example long cylindrical sections are split into lengths of not more than about 10 diameters Consider where the X 0 position is for the mandrel this is the datum position for the mandrel The mandrel must be located with reference to the winding machine datum This is discussed further in post processing under the heading XDAT Carriage Axis Datum The positive X axis direction of the mandrel must be in the same direction as the positive direction of the machine carriage axis A mandrel envelope is a clearance surface around the mandrel on which the fibre dispensing head will move It is defined in the same way as the mandrel shape When creating an envelope the user should consider several things It gives better control to have the dispensing head close to the mandrel at all times If clearances are
139. le layer winding along the mandrel with a dwell and outward wind a second dwell and a return wind The winding program is repeatable The See 1 7 3 2 option is also available for winding hoop programs with several stages These user specified parameters are Cylinder Radius 68 Cadfil Help 8 53 V7 63 This is the radius of the cylindrical mandrel Clearance Radius This is the distance of the fibre dispensing point from the axis of the cylinder This MUST be bigger than the mandrel radius Start X Position This is the start X position of the winding in mandrel co ordinate system The actual carriage position machine co ordinates can be fixed by the See 1 6 13 3 and See 1 6 13 9 during post processing Length Of Winding This is the length of the hoop winding band centre to band centre This can be positive of negative as the winding will be from the Xstart position to Xstart position Winding length The overall extend of the winding will be 1 2 a bandwidth more at each end as the band centre position is programmed Fibre Band Width The width of the fibre band used to determine the winding angle such that the cylinder is fully covered by one circuit i e the carriage Advances one band with for each full mandrel rotation Dwell Angle Ist End Deg This is the amount of mandrel rotation with no carriage movement at the start of the hoop winding It can be zero Dwell Angle 2nd End Deg This is the amount of m
140. ll Dist End 1 End Plane Pos 2 Payout Clearance Mode Extra Dwell Distance End 2 G Envelope from DXF Dwell Hold radius Payout Clearance Band Width o o End Turning Length Wind Angle Degrees V Mandrel rotation in direction Friction Mu e g 0 2 ivr Cua rame Browse DXF Files End zone speed over ride Boss Rotation Angle Note that of the parameters may be greyed that is the user cannot select of enter data This is because those options are not used and are retained for compatibility with different software options or for future options Mandrel Start X Start and Mandrel Finish X These define the length X finish X start of the winding program and where it is positioned relative to the mandrel origin the x 0 position The position of mandrel origin in the machine will depend on the machine datum s and the XDAT parameter described elsewhere in this help file under post processing Minimum Arc length around the section is the typical spacing of data points along the path on the mandrel surface the units will be the same as the mandrel units usually mm or inch For reasonably accurate winding about 8 points per rotation for higher angles is more than adequate however when the user looks at the Cadfil graphics the path will appear not to be smooth If good graphics are required use a small spacing Please note that calculate time will be large and the data files and winding programs will be large if
141. low Spar Winding mandrel from DXF Mandrel Start x i Cancel Mandrel Finish x J Dome length g Elliptal boss Dim A foo Read Param s Elliptal boss Dim B foo Wite Params Envelope Vertex foo Minimum arc length around Section E End Plane X Pos 1 re Extra Dwell Dist End 1 foo arene Payout Clearance Mode Extra Dwell Distance End 2 foo amp Envalone Hom OXF Dwell Hold radius zm S E Band Width lt End Turning Lenath a 0 Wind Angle Degrees e g MV Mandrel rotation in direction Friction Mu e g 0 2 po o oo DXF File name OoOo Browse DXF Files End zone speed over ride 100 Boss Rotation Angle CALCULATE Help iie Note that of the parameters may be greyed that is the user cannot select of enter data This is because those options are not used and are retained for compatibility with different software options or for future options Mandrel Start X Start and Mandrel Finish X These define the length X finish X start of the constant section of the mandrel and where these sections are positioned relative to the mandrel origin the x 0 position The position of mandrel origin in the machine will depend on the machine datum s and the XDAT parameter described elsewhere in this help file under post processing 108 Cadfil Help 8 53 V7 63 The dome length is is the length from the section where the mandrel start to change shape to where it meet the shaft This length is assumed to be the sam
142. mandrel section of the software A warning is also given for meshing the mandrel with fewer than 16 elements per revolution This is for user information purposes and does not stop the user from continuing with the fibre path development section of the program This minimum is recommended to enable the system to gain an adequate surface representation of the mandrel A trade off is required between the accuracy of the mandrel definition and the computational time required A high number of elements per revolution will increase the time for path calculation not only in this section of the program but since the file generated is required in later parts of the system then it will also affect the speed of path generation in these sections also This very high definition of fibre paths is unnecessary to generate accurate NC programs A number of elements value of 30 is suitable for most purposes See 1 3 3 1 3 3 Fibre Path Start Position When deciding on where to start the fibre path the user must decide on what are the main requirements of the path he wishes to generate An appreciation of the various ways in which the fibre can be started will simplify matters The user ought to consider the following requirements of fibre paths 1 Is there a fibre winding angle that is necessary at specific axial locations on the mandrel 2 Is there a requirement for the path to close down to a boss on the mandrel end s or to have a specific
143. mpatible with the relevant winding machine controller Post processing is divided into a number of options dependant upon machine axes available and which axes are to be used These options enable a program to be generated using a different machine control strategies Various data files are supplied with CADFIL which enables the user to configure their system to their own specific requirements These and other CADFIL files are discussed in See Appendix D Cadfil Files The user is initially required to define the mandrel geometry This is achieved within the See 1 2 1 mandrel edit Alternatively the mandrel data See 1 2 3 such as AutoCAD via a DXF file and option described else where in this help file The edit option asks for an existing mandrel file mnd extension The mandrel geometry is defined by the input of data points in the form of X R co ordinates X being the position along the mandrel s axis of revolution and R the component s radius at this position A three dimensional surface mesh is automatically created from this information in the fibre design section Once the mandrel has been generated the user can create fibre paths on it by selecting the See 1 3 1 option from the Cadfil main menu The mandrel geometry determines the path of the fibre once the initial start point and fibre direction have been entered and can only be varied by a small amount dependant upon the coefficient of friction between the fibre the r
144. n fixes remembers the current fibre position such that the path before this point cannot then be deleted If is is attempted to deleted past the fixed point a warning message will be given Clicking the Unfix Point button will cause to software to forget the fixed point If a point has been fixed the path is advanced and the the fix point button is pressed again the new position will become the fixed point and the previous value will be lost Help The help button launch this software topic OK This button closes the dialog however the dialog can be left open add you can advance or delete the path by clickimg on the Cadfil Graphics window reverting to this dialog to adjust the parameters 1 3 13 Views Menu Fibre path viewing enables the user to see the fibre on the surface of the component from any direction he desires and permits the use to zoom in on an area of interest and pan or move the view point along the fibre The fibre path and mandrel viewing menu is reached by selecting VIEWS option at the See 1 3 10 or from the See 1 4 7 The options are selection on a n easy to use windows dialog box and are described as follows OK Returns to the previous menu and redraws DRAW Refreshes the screen with the latest draw options and remains in the views dialog X Y View This is the default view and the user sees a side profile of the mandrel looking normal to the mandrel X Y plane X Z View This is a side profile of the mandrel loo
145. ndrel end view is selected from the VIEWS menu See 2 2 1 3 9 Difficult mandrels Cadfil Graphics Window Start in Concave area at a high ae eg 85 B SEA A aE H 1 3 10 The fibre path creation menu This menu controls the generation of fibre tracks on the mandrel surface Through out path generation the current path X position X mandrel radius R winding angle A point number N and friction status are displayed in the text window 22 Cadfil Help 8 53 V7 63 Finish and Save Action Friction Step Delete View Options Rotate About axis Redraw Restart Path Test Hoop Pts The menu options above are described below Finish amp Save This exits to the main menu and the user is asked if he wishes to save the fibre path data before exiting Having saved the fibre the option to proceed to See 1 4 1 Action This option advances the fibre path by the current step value with the current friction setting As a shortcut a left mouse button click on the Cadfil Graphics window has the same result Friction Step Pops the See 1 3 12 with allows the user to set parameters for the path creation As a shortcut a left mouse button click on the Cadfil Text window has the same result Delete This option retreats the fibre path by the current step value with the current friction setting As a shortcut a right mouse button click on the Cadfil Graphics window has the same result View Options This enables the See 1
146. ndrels can be used The user creates a control file with parameters such as plate height width and thickness band width wind angle and required sample length and some other control parameters The software automatically creates NC data for 3 6 axes for most applications only 3 axes are required mandrel rotation carriage and cross feed Fibre and payout paths and a mandrel definition can be automatically created for visualisation in the CADFIL I software The machine positions are calculated to give close control of the fibre payout and fibre speed to prevent fibre breakage on the plate edge High quality windings can be produced by the software 88 Cadfil Help 8 53 V7 63 Because flat plate windings have poor fibre consolidation some pressure is required during curing This can be done by curing in a press but satisfactory results can be obtained by curing the wound plate between steel sheets with a weight placed on top Following selection of the PLATE parametric option at the QuickCAD menu x PT ATE PARAMETRIC No OF POINTS ON TURN RADIUS FACE ADVANCE PARAMETER WIND ANGLE DEGREES REQUIRED WIND LENGTH FIBRE BANDWIDTH PLATE HEIGHT PLATE WIDTH PLATE THICKNESS CLEARANCE TOP EDGES FACE CLEARANCE END OVERSHOOT CLEARANCE START POS FROM PLATE END See 1 7 9 2 1 7 9 2 Plate parametric data entry No of points on turn radius This parameter NPT is an integer whole number that must always be odd
147. ngth is required as this otherwise can result in the elbow rotating forward and backwards in the winding machine rather than is a constant direction 100 0000 See 1 7 6 2 1 7 6 2 Elbow parametric data entry R Rc A L Yoff define the mandrel geometry and See 1 9 14 The mandrel axes are also shown The sign of Yoff is important as this is measured in the mandrel Y direction from the mandrel origin to the wind axis The point per rotation N defines the number of data points per rotation on the fibre track around the mandrel a small value e g less then 8 could lead to inaccuracy in the winding A large value leads to an increase in the size of data files and the final NC data For most purposes a value of 12 is a good compromise The band width Bw is the actual width of the fibre tape or band that will govern the separation of the fibre paths on the mandrel surface The Free fibre length FI is the distance between the fibre contact point on the mandrel and the control point at the end of the payout device on the winding machine This option is displayed if the ELBOW1 parametric option is selected If this distance is very short the risks of contact with the machine and the mandrel are much greater 75 Cadfil Help 8 53 V7 63 Because of the complexity of winding head geometries particularly on 6 axis machines it is not possible to guarantee that there will be clearance between the mandrel and machine at all
148. ntered and the winding angles that have been achieved within the fibre path If we enter a different number of cycles for example twice the number of fibres as the minimum value calculated the CADFIL system will compensate by halving the incremental angle to the next fibre in the band pattern Hence since the fibre has a fixed bandwidth the fibre will now overlap its adjacent fibre by 50 Informing the CADFIL system that we require a number of cycles less than that calculated unless we also modify the fibre bandwidth to compensate will result in a the fibre being laid in a basket weave pattern or one which has holes in Number of times to repeat program Another method by which we can modify the thickness is by using the combine programs option on the NC Post Processng menu This options used to combining different winding programs e g heklical and hoop programs to make a continuous program However it also allows the user to define the the number of times a program is repated In using this method the second layer wound does not take into account the thickness generated by the winding of the first layer More information this option cab be found in the section on See 1 5 1 This method does not use overlapping of bands to create the required thickness and will create discrete layers often leading to a better laminate The same effect can be eached by editing the NC data and changing the number of circuits for the progr
149. o set the See 1 6 12 which are also set in the SM file See 1 6 5 1 6 3 Post Processor Configuration LOGICALS In the post processor block definitions for the layout of SPF and MPF there are numerous logical variables that can be used These have the format NAME for example LAB AX 1 In this case the LAB AX 1 is the axis name label for axis 1 the mandrel rotation So if the mandrel rotation axis label has been set to A then wherever LAB AX 1 is specified the value in this case A will be applied There are numerous logicals some will be essential for creating a working program some can be used to add optional information to the program for example CADFIL VERSION can be used to add the version of Cadfil being used to the program FEED Current value of feed rate or speed variable LINE NUMBER SPF amp LINE NUMBER MPF Are the current SPF and MPF program line numbers The first line in the main program MPF is set by the value LINE NO START MPFEF and the line number step is set by LINE NO INCREMENT MPF For the sub program file SPF the values are LINE NO START SPF and LINE NO INCREMENT SPF LINE NUMBER SPF is the number of the next line i e the current line number plus the line number increment The maximum line number the controller can support is set by LINE NO MAX If this is exceeded the first line number is then used thus it will not be unique LAB AX n whe
150. o ways the first having a Skip Factor of one and the second a Skip Factor of two The band patterns that are possible are a function of the number of machine carriage circuits cycles that are required for one layer on the mandrel As the number of cycles increases the number of band pattern possibilities increases For a given number of cycles CADFIL automatically calculate all the different band pattern possibilities the user can then select a suitable pattern from these The See 1 9 8 figure shows a typical user dialogue for band pattern selection As can be seen the user is first given the number of cycles and the total rotation of the path around the mandrel The items on the table header are The option number The band pattern The mandrel rotation per cycle that will result from selecting this pattern target angle The angular change that is the change in mandrel rotation required to achieve this pattern The Progression factor PROGF The amount by which the progression factor differs from the ideal value of 1 0 The ideal situation is to have no modification to the path i e to have a progression factor of 1 000 When the post processor suggests possible band patterns it orders them such that option 1 is the nearest to 1 000 and option 2 is next nearest etc If the progression factor is more than about 0 05 from 1 000 i e outside the range 0 995 1 005 then fibre slip may occur Thus such options are not
151. occurred In this case it is recommended that the user post processes again and decreases then winding speed value in the NC See 1 9 17 so that no axis speed exceeds 99 9 Please note that for Cadfil Pipewinder multi pipe the speed is set for each SPF in the data table and should be adjusted there For a single SPF post process job the speed information can also be seen in the speed graph shown at the end of post processing 56 Cadfil Help 8 53 V7 63 1 6 13 7 NC Part program main and subroutine numbers Please note that on most modern NC controllers program numbers are not required as the names of the PAY or CTL file used can be used directly for the main and sub program names rather than numbers In the case the SM post processor configuration file is set so the user is not asked for program numbers The user is prompted for the program numbers to use in the NC data These are checked to ensure validity for the particular controller the user being prompted until a valid input is supplied The numbers supplied are whole numbers and there usually being a range for valid numbers for example 1 to 999 or 1 to 9999 On some controllers it may be possible to have the same main and sub programs numbers and other controllers may not permit this There may also be certain program numbers on the machine that are reserved for special purposes This is not checked for The user is advised to read the documentation for the specific machine
152. ollowing sections outline the methods for attaining specific fibre path characteristics which may be required by the operator See 1 3 6 1 3 6 Creating a fibre path Having created a mandrel as described in previous sections a fibre path can be created From the CADFIL initial menu select the Create Path option The user is asked to enter select the mandrel file name and is then asked for the Number of elements per revolution This is the number of elements around the mandrel and is discussed in the See 1 3 2 section The start conditions for the fibre track is then requested Once the initial start position and direction has been selected it is only possible to make small modification to be basic geodesic path trajectory The only method available is to use the friction that exists between the resin fibre and mandrel being used This section 19 Cadfil Help 8 53 V7 63 describes how the path is started and the subsequent sections discuss the best methods of start point selection to achieve specific requirements When the path is started the mandrel is drawn in the display area in the default X Y SIDE view The user is then requested to specify the X location of the start position i e the position along the mandrel axis The options are Typelf the X co ordinate of the start point required is known then this option is used The user is prompted Enter start position The start position entered must be in mandrel units and i
153. omposite FMR Volume fraction of fibres in composite FVR The units of Resin Density and Fibre Density must be consistent 1 10 3 4 Volume fraction from mass fraction calculation FVR _ ____ 0 Ps Ee yer Resin Density Dr Fibre Density Df Mass fraction of fibres in composite FMR Volume fraction of fibres in composite FVR The units of Resin Density and Fibre Density must be consistent 1 10 4 Appendix C Other Languages 1 10 4 1 Other Languages In the Cadfil system directory usually C Cadfil V7xx there is text file called Lang dat This file is a text file that can be viewed and edited in a program such as WordPad Instructions on how to change this file to configure Cadfil for another language can be found in this file a fragment of which is show below REM This is the Cadfil text string file REM This file is a template to set up Cadfil REM for use with languages other than English REM REM text message Some or all of the messages can be translated REM Into another language and if this file is then returned REM by disk1 or Email to Crescent we can use it to configure REM for that language and return an updated version of the software REM REM Reference numbers greater than 10000 are the text on 141 Cadfil Help 8 53 V7 63 REM the Cadfil menus I E 10101 is menu 1 item 1 10102 is REM menu 1 item 2 10310 is menu 3 item 10 etc REM REM Menu strings can have a amp which sets the following ch
154. on of the fibre track relative to the mandrel origin in the mandrel axis system and units for axis n In addition to the linear axes carriage cross feed vertical there may also be some eye roll or eye yaw motions These assume an origin for the motions The zero position for these rotational axes is a function of both the machine and payout eye orientation in the machine Some machines have a zero position whilst on others the zero position must be set when the machine is started up Cadfil has an internal zero position assumed for the eye roll axis axis 2 This is as follows imagine the cross feed axis is horizontal the fibre is being dispensed from a roller and the axis of the roller is vertical The zero position is with the fibre coming of the positive carruiage motion side of the roller i e the side of the roller that is in the carriage axis positive direction In this case for normal winding which starts at hoop in moving to the start position the eye roll axis will rotate either or 90 degrees dependant on the direction of mandrel rotation As a consequnce the majority of 58 Cadfil Help 8 53 V7 63 winding machines have a OFFSET AX 2 value of 90 or 90 or the equlvaent in the machines units The eye Yaw axis axis 3 zero position is assumed to be in the straight ahead position that is with the payout arm normal to the winding axis this Cadfil Zero can be modified to suit the winding machine setting OFFSET A
155. onsultants have a number of specialised programs that can be configured from the QuickCad menu The screen options could include those shown below See 1 7 4 1 See 1 7 2 2 See 1 7 3 1 See 1 7 3 2 59 Cadfil Help 8 53 V7 63 See 1 7 9 1 See 1 7 6 1 See 1 7 8 1 See 1 7 10 1 Click for a link to See 1 4 2 entry in payout path creation QuickCAD options are specific to a type of geometry e g dome ended cylinders The user enters basic parameters such as wind angle cylinder diameter band width etc This data is saved as a PAR file and can be saved retrieved or edited Using this data the mandrel data fibre path data and payout data is automatically created and then the payout path data is post processed to produce NC data by the normal options The parameters for different the options are discussed in the following sections 1 7 2 Pipe Winding 1 7 2 1 PipeWinder Multi pipe This software driven from a single dialog screen as shown below cadfil70 Multi Layer Pipe Winding 100 000 150 000 ua 25 000 O Exit Band Pattem Mode Select 300 000 hie sen 0 Automatic Use Minimum Dwell 3000 000 Calculate Feed Rate Mode Select x 0 150 Update 0 Constant F value 7 Circuits per Band Pattern Dwell Rota on Wind Time Waste ateachEnd Minutes Length 12431 0 432 I 0 758 279 8 98 289 25 iit 82 721 i TTT Layer Number reties pete pRa Jews ER e SS j fea 3 Tf 2
156. or though in some cases this can be done by See 1 4 4 where the mandrel rotates with no other motion 31 Cadfil Help 8 53 V7 63 The progression factor is the ratio of the desired total rotation needed to achieve a certain band pattern structure Target Angle to the total rotation of the generated path around the mandrel for one circuit Actual angle Progression factor Target Angle Actual Angle See 1 9 10 As can be seen the successive bands are laid adjacent to each other It is very unlikely for a fibre path to return to a position exactly one band width around the mandrel from its start position Thus in order to achieve this the angles of rotation of the mandrel are modified along the fibre path generated If the path returned 180 degrees out of phase with the start point and if the total rotation from start to end is quite small say 1 to 3 revolutions for example then the modification to the path progression factor would be large This would be likely to cause the path to be unstable and slip In this example a band pattern of 2 would be more appropriate See 1 9 10 can also be seen in the figure In this case the coverage of the mandrel now progresses from two initial positions For band patterns higher than 2 there will often be more than one possible band structure and thus the post processor will give more than one option for a particular band pattern An example can be See 1 9 10 could be performed in tw
157. or the NC data The most probable cause being that this disk is full ERROR READING PAYOUT FILE LINE NUMBER nn This error is generated when there is a data format error in the payout file that is being read This error was first detected on line number nn This will usually indicate that there is a data format error on that particular line or that the end of the file has been reached unexpectedly The format of the payout file can be found in the appropriate appendix ERROR OPENING FILE xxxxxxx Where xxxxxxx is the name of the file being opened This indicates that there was an unexpected error opening this machine data file contact CCL M C AXES INCOMPATIBLE WITH THOSE AVAILABLE CCL internally configure the post processor for the number and type of axes on the customers winding machine This error occurs when the post processing option requires axes that the machine does not possess For example if 5 axis post processing is selected when the machine only has 3 axes 118 Cadfil Help 8 53 V7 63 1 9 Figures 1 9 1 Mandrel XR Edit Dialoge Box Mandrel X R Data Entry No symmetry IV Point Labels Mandrel Data c X End Symmetry Y Draw Expanded Envelope Data C X End Symmetry j x R POINTS RADIUS Click on line of data to edit OK Add Data Delete Data Help 1 9 2 Graphics Window in Mandrel Envelope X R Edit Cadfil Graphics Window Lol 119 Cadfil Help 8 53 V7 63 1 9 3 Edit XR Data Record
158. ore starting some planning is required as we may end up creating several files amd complete the path generation The band p it makes things easier to have a logical naming system 2 15 Slideot page in the winding sequence we have suggested names for the parate am co ent The vessel desi d V120 agd the ndi are Emai agase W epl co H P Poo vansition DEE O te Wd Agat t15 degrees at 20mm Ba in the winding sequence i e 01 02 03 End openings are the same 2 16 Slide 1 Email sales cadfil com Web http www cadfil com CNG Tank example Page 1 of 22 26 WeAwill now remake this program with non s the LH nd cap 70 at the RH end As we progra and RHjends 27 Pick the Vessel With End caps option fron V120P03 PAR we s ecteartier Note weticktin 2 17 Slide Non Geodesic Winding gf Geehtes eae bD safes cadfil com Web http www vadfil com CNG Tank example Pasar op fit rs S FEA ae Ife eit Email 2 18 Shier geometry for this vessel is defined by the data parameters in the red Email ciggle anesthe pictyxg below gttp www cadfil com CNG Tank example Page 1 of 22 shows an ex Layer 01 Hoop winding 2 19eSlid ciis a double hoop layer that will wrap from Position A to B and then Email PACK tego bahirBom A WBA AS hentia Sad oMAnetpieolapagand tat will Machi start at position C in thif instance the transition path is likely to be better from A to C ea directly from B to C wopld always slip AD menu s os the multi
159. orientations and positions When winding an NC program for the first time it should always be run slowly such that the user can check clearance and stop the machine quickly if necessary It may be necessary to re generate the program with a greater free fibre length or to use a different post processing control strategy Eind The picture above left shows part of a payout path from the Payout path viewing options Each blue mark represents the position of the feed eye it is easier to imaging the mandrel as being stationary and the feed rotation around the mandrel Near the centre of this path a problem is evident as the paths circulates around the mandrel but does not circulate around the winding axis the dashed line This cannot be wound and 76 Cadfil Help 8 53 V7 63 if post processes the mandrel will rock forwards and backwards The solutions are to adjust the wind axis position or to increase the clearance free fibre length The same winding with the problem fixed can be seen in the picture above right If the ELBOW2 parametric option is selected the display will show the option Control Cylinder Radius The radius dimension entered is required to be greater than the maximum radial point of the mandrel away from the winding axis to be used This enables the winding of an elbow component on machines without a cross feed axis or only a manual cross feed axis For a two axis mode the over travel past t
160. osition is selected If one or both sides of the box have zero side length the zoom area will not be selected Having successfully picked two points the software will redraw the current image fitting the selected area to the screen Note that if the user picks a zoom area with no fibre or mandrel in it then the screen will be empty after redrawing The ZOOM is reset to full screen whenever a view is selected as the VIEWS menu Zoom Factor Zooms based on current view centre i e 0 5 halves the scale i e display is smaller and 2 0 would double the view scale Zoom ALL This resets the zoom to full screen Pan in View This allows the user to move the view position move the mandrel across the screen and can be useful in conjunction with the ZOOM facility The user is requested to enter two cursor positions The direction from point one to point two is the direction in which view point eye moves and the distance moved is the distance between the points The pan view port is reset when a new view is selected Shade None switches back to normal display options i e all shading is switched off Mark Nodes is principally of use for non axisymmetric application When selected the use is asked for a node number from the mesh database If this node does not exist the system will beep If it does exist a marker will be placed at its location on the screen Normal Vectors when this option is selected the element normal are displayed with a line f
161. ositive AX5 direction being away from the mandrel 38 Cadfil Help 8 53 V7 63 The directions of the other axes then follow directly from the adoption of a right handed set RHS The FWM may not use such a system so the signs of the axis motions are modified according to the signs of parameters AX STATUS n defined in the machine configuration SM file Various post processing options can be supplied using up to 6 axes dependent on the axis configuration of the machine and the nature of the winding to be undertaken The standard system options supplied are the See 1 6 5 The winding can be divided into three main areas these being 1 Winding with a single tow 2 Winding with multiple tows wide band width or3 Winding with tape The standard CADFIL post processors are the 3 axis and 4 axis systems The three axis post processor uses the machine axes AX1 AX4 AX5 and the four axis system uses machine AX1 AX4 AX5 AX2 axes The 3 axis system is primarily for winding using a payout eye with a single tow or perhaps a narrow tape the 4 axis system is for use with multiple tows using a roller or comb payout system The additional eye roll axis motion removes the sliding action of the tows across the roller The post processor is independent from the path generation software and is configured specifically for particular customers The various post processing systems e g 3 4 or 5 axis systems can be accessed f
162. r 2 0 128 1 9 16 Front amp Back faces of plate with face advance parameter 1 128 1 9 17 NC Feedrate Dialogue Arccscaacuiernttonsanditecens Sicrandehdewds oecpuacwieeSnaetee 129 1 9 18 Spar winding Parameters eseeseeeseseeseseresrersrssresressresressrsstssreseresesreseres 129 1 9 19 QuickCad Sphere Parameters ennsesseneseeeseeeeseeeseeesseesseeessersseresseesseessee 130 1 9 20 Machine offsets and Datums sseseessesesessesessessressersresressessresrereresresreseres 130 TO Appendices eienenn einet ao e EEA OE EEE E anes 131 PAO Cail Install tion ranon aa ceed Capel ieee invaded 131 1 10 2 Appendix A Cadfil file formats csscececesseeeesesseerseneeteeneeseessereoee 133 1 10 3 Appendix B Calculavions jcsscsscncsiseseoestasicvsscaneentessvaceconiagvestavsavaceavedeessenies 139 Cadfil Help 8 53 V7 63 1 10 4 Appendix C Other Languages isc i0ccpcussiiaelseitnswsstna heashedpen thc accaetoevna tea 141 EA ETa E a ace ea rir ree TG rN eee Oem reer aoe ron net TY eee Ser Cree ere toe er 143 1 111 Examples Introd ctiOn sorires eno esne ire 143 1 11 2 QuckCAD CNG Vessel tutorial 01 0 0 ccccccsssssccceccceeesessssseeeeeeeees 143 1 11 3 Aluminium Bottle QUICKCAD 0 cece cccccccccesssssssseceeeeceeesenstssseeeseeeees 143 Addenda ddr ea hoon glotapheh Lanes gabe aaa a ica nv A gta haa ede ooh tisha A 147 2 1 USB Datakey DRI Joar e E E EARE E 147 2 2 Difficult mandrels ainor ae O
163. rams area e Creates a Desktop shortcut for Cadfil STEP 2 Install drivers Cadfil uses a security device called a Datakey This is a See 2 1 USB port device See 2 3 parallel port devices are not supported after Cadfil version 7 25 131 Cadfil Help 8 53 V7 63 Cadfil copies a driver file to the C Cadfil cadfil7xx The driver install program is called DK3win exe A shortcut in the Cadfil programs group on the start menu can be used to run this install Please note that Cadfil Install files downloaded from do not usually include the drivers to keep the file size smaller Driver installation is not required if the user is installing an updated version of Cadfil Drivers can be downloaded from the web page STEP 3 Attach Datakey Attach the USB datakey The first time a USB key is used you may get the message that Windows has found new hardware and is loading drivers please wait for this to complete This message may also occur if you plug into a USB port that has not been used for the datakey before STEP 4 Apply a licence file You should have been sent usually by email a small file usually called lic dat This is required when you run Cadfil for the first time after an install Place this file in a convenient location on the PC for example on the desktop You can now run Cadfil my clicking the Cadfil7 icon on the desktop or in the start menu Programs Cadfil7 group Problem Solving You may find that most of t
164. re has been an error opening the mandrel file on disk or writing to it This could occur for a number of reasons 1 The file name the user has supplied could be an invalid DOS name for example the characters lt gt are illegal Refer to your system manuals for valid names After clearing the error message the SAVE option can be re tried using a new name 2 The disk drive could have no space left on it If this is the case you will need to exit from Cadfil without saving the file and to create some more space or run Cadfil on a different disk 3 If you are running from a disk root directory there is a limit to the number of files directory entries that exist This limit may have been reached in which case you will need to exit from the program without saving your data and either change directory disk or delete some unnecessary files 4 An unexpected error If an error occurs that cannot be explained by any of the above then contact CCL with the details UNABLE TO OPEN MANDREL FILE This error message occurs when the software is unable to find a mandrel file to read that is the file specified by the user does not exist in the working directory After clearing the message the user can select the option to read the file again and supply a new name ERROR READING MANDREL FILE This error occurs when reading the mandrel file if the data in the mandrel file is corrupt or not in the correct format The format of the m
165. re n can be 1 to 6 These are the names labels for axes to 6 AX INC n where n can be 1 to 6 Is the current increment motion value for axis n POS n where n can be 1 to 6 Is the current absolute machine position value for axis n SPOS n where n can be 1 to 6 Is the absolute machine position of the very first position the start position for axis n NO PASSES Is the number of circuits for the current SPF CADFIL VERSION 43 Cadfil Help 8 53 V7 63 The current Cadfil version e g 7 35 DATE Gives the value windows reports for current date and time in the following format 06 NOV 07 08 38 07 MDF NAME The name of the post processor configuration sm file being used SPF NAME The name of the current SPF often the current payout file name MPF NAME The name of the MPF CTL FILE NAME Name of the CTL file when multiple layer programs are being processed if there is no CTL file this is the name as MPF NAME Qn where n takes the values to 4 These are the 4 terms of the quaternion function for post processing using a industrial robot The four Q values Q1 Q2 Q3 amp Q4 define angular the orientation of the payout eye robot tool BLANK LINE Adds an empty line a line with a single space TENSION VALUE n where names takes the value 1 to 3 In the sm file there user can define up to 3 tensions values For example these could be high
166. rea i or eal lease ae that bis are Directic iffet pt gia f giae BU SAAND Ae Og E VALGE SHREY be R Kendar input 2 p Phe e clic Q give context sensitive ine of At a can be 2 dP are n AMBRE SPS ee context i ta ca i KERAPA a EM nM irwbN Fede oine ese ER the et i N amp e e clearance radius is mesje ihi inp 14 OAR OG CE the surface of the cylinder A BUN ge after Ci dees not need to be chang e Enter the planne C ZO heittrom the Nem Wesanephateentre of He fibre band so we must adjust b g edge of the band to slip down the end cap so we must adjust away from the dome a little 2 95 fuf Payout yhe fis se jectosiew Options picture top right 7 tive aienosidilos cnichegupidgt abhi pobiGieRlANh Abe Mbheinent in Email Ree 1 doweP menu EN Baras land th e draw Nac 6 Ij ae fe E ee TE e ae en A TT PAUP HAR thom Poit HN e ame that Bando faucet 16 Hi al e a wind angle df5 3 degrees on the Mel If we cofi pecs taste ihe Maghing eval p 155xSin 15 155 being the radius of the cylinder el 5 We will thus wind at hoo from noasition 1 to nosition 7 Cadfil Help 8 53 V7 63 2 23 Slide 1 Email sales cadfil com Web http www cadfil com CNG Tank example Page 1 of 22 2 2 Slide 1 Email Web http www cadfil com CNG Tank example Page 1 of 22 Slide from the payout viewing options the next step is to start a 2 25 Finding This is file that defines a sequence of programs
167. recommended but may be feasible 32 Cadfil Help 8 53 V7 63 In the See 1 9 8 the user could click on line 1 for a band pattern of 13 or line 2 for a band pattern of 11 The user may change the number of cycles to allow different patterns to be displayed and to See 1 4 6 For example if CADFIL calculated that 186 4 cycles where required for coverage this would be rounded to 186 The cycle range in the boxes at the top of the band table would be from 186 cycles to 186 cycles By clicking into the boxes the user could change these values to be from 185 cycles to 187 cycle and then click the recalculate button The best band patterns using the new data would be displayed The dwell split feature is discussed under the topic See 1 4 4 If the cancel button is selected then no band pattern modification is applied This should not be used for standard axisymmetric CADFIL files as the winding pattern produced will usually be random Certain special programs parametrics can generate PAY files that have the correct band pattern already built in to them and thus the band pattern modification should not be applied 1 4 4 Band Pattern With Dwell Winding On the See 1 9 8 there are buttons to switch from See 1 4 3 to dwell winding In dwell winding the modification to mandrel achieve a band pattern is achieved by additional mandrel rotation at the See 1 9 4 Normally the dwell rotation is split equally 50 50 between the two turning
168. renced in the fibre path file The prompt Thickness file required y n is then given A thickness file is not usually required but if it is a file name must be specified this file will have the default THK extension A thickness file must be generated if the user wishes update the mandrel later RESIN DENSITY 1 10 FIBRE DENSITY2 60 NUMBER OF ROVINGS1 FIBRE TEX2400 THICKNESS CONSTANT K 1000 00 FRACTION MASS RATIO0 60 FILTER ANGLE DEGREES 12 00 FILTER LENGTH100 PAYOUT CLEARANCES0 00 FIBRE BAND WIDTHS 0 30 Cadfil Help 8 53 V7 63 The first six values above are used to estimate the cross sectional area of the resin impregnated fibre bundle to allow the thickness of the winding to be calculated When the user later specifies the band width the band thickness can be estimated The calculation is set up for default units but can be modified if required See the appendices See 1 10 3 2 See also the section on See 1 4 6 The See 1 4 5 can be used to reduce the number of data points in the payout path and are discussed in one of the following sections The PAYOUT CLEARANCE is used to create the default envelope around the mandrel If the mandrel file has an envelope defined and this was selected at step 4 then this value is ignored The PAYOUT CLEARANCE value entered MUST be in mandrel units The software now calculates from the data input the number of cycles required to cover the mandrel This line is displaye
169. right hand friction is used to turn the path faster as shown in the second picture With non geodesic winding on a flat ended mandrel like this there a risk of fibre slippage often the part will wind ok at one speed but will slip if the winding is speeded up The solution is to use dwell winding to add rotation to wind the fibre around the shaft as shown in the third picture 1 4 5 Filter length and filter angle To generate an accurate geodesic path the mandrel must have a relatively large number of patches or elements Fibre positions are calculated each time the path crosses the boundary of an element The number of data points on the fibre path is much greater than the number of points required to accurately control the machine Filter length and angle are used to remove filter out surplus data points Subsequent data points on the fibre path are selected such that the distance between the points on the mandrel surface is not less than the filter length and the angle between the path direction vectors for successive data points is not greater than the filter angle The default values are suitable for most purposes The filter values cannot be zero and the filter length is not permitted to be greater than 20 Using very small filter values can lead to many very small motions on the winding machine In many cases this leads to rough operation of the machine and can lead to an increase in winding time 1 4 6 Thickness modifications Within
170. rom the NC Post Process option of the Cadfil main menu See 1 6 2 1 6 2 Post processor configuration SM File At version 7 all post processor configuration is in a file with the SM extension The file is usually found in he Cadfil install directory When Cadfil is run a file called default sm is always read If is is not found in the install directory a windows file open dialog box is shown and you must browse to find it If on reading the SM there are errors in it there is than an option to view the error log which will identify the problem s If there are errors in the file all the post process options will be greyed out that is you will NOT be able to post process On the NC Post Process menu there is a select winding machine option which allows the selection of a different SM file Thus if you have two different winding machines you could have machine namel sm and machine name2 sm Each time you post processes the text The Active machine configuration is gt machine name snv is displayed in the text window so you know which configuration is in use 39 Cadfil Help 8 53 V7 63 If you change a SM file while CADFIL is running you need to exit or re select the SM file using the select winding machine option to ensure the changes are being used The SM file is a text file that can be viewed or changed using a text editor such as Notepad If you use notepad set Word Wrap
171. rom the centre of the patch that is normal to the patch surface The outer end is marked with a marker The markers will be re displayed even if the view changes If this option is selected again the feature will be switched off Shade Linear this selects one of the advanced 3D solid rendering display options In this mode all solid objects such as the mandrel and any payout head block definition will be rendered in a pre set colour palette to reflect a light source which is behind the view point of the user A true hidden detail image is created using Z buffering techniques These images can be captured as Windows bitmap files using the VIEWS OUTPUT option Such images can then be read into presentation packages such as Corel Draw and Microsoft PowerPoint to produce high quality report and presentation materials 27 Cadfil Help 8 53 V7 63 For a payout path in conjunction with the fibre dispensing head block definitions see PAYOUT VIEWING the user can step through a winding program looking at a realistic 3D solid model and can easily visually assess the winding program and if there are any problems with machine mandrel contact This essential for non axisymmetric geometries and multi axis winding machines as the interaction of the machine and mandrel is very complex The only alternative is to test the program on the winding machine losing valuable production time This options renders the objects based on the normal direction of the surfac
172. s and the ply angles required for each layer The clearance envelope is spherical with a cylindrical clearance around the shaft s SPHERE3 Equal or unequal openings with automatic wind angles 86 Cadfil Help 8 53 V7 63 This parametric is for vessels with equal or unequal polar end openings the users specified the end openings and the number of layers The ply angles required for each layer are calculated automatically The clearance envelope is spherical with separate cylindrical clearances for each shaft The polar opening at one end can be zero or can be specified that the band crosses partially over the pole See 1 7 8 2 1 7 8 2 Sphere parameters described Show Picture The parametric data for the Sphere parametric follows Data entry for the other sphere parametrics is similar eS PHERE3 PARAMETRIC Sphere Radius Filament Band Width Polar end opening radius Number of band sets Number of points per circuit Spherical clearance radius End shaft clearance radius The Sphere radius and polar end opening define the winding geometry The polar end opening is at both ends and the inner edge of the fibre band for the lowest wind angle should just touch the opening diameter The highest wind angle is 90 degrees and this is a single band around the equator A number of winding angles layers are created equal to the number of bands sets with constant changes in wind angle between the highest and lowest angles layers describe
173. s motion can be broken into a number of smaller motion blocks If PIPE MAX CARRIAGE INCREMENT 1000 was set a linear motion on the carriage of 8900mm would be slip into 9 equal portions such than none exceeded 1000mm On some machines this feature could be used to help in recovery from power failure or to help in motion smoothing or to overcome some controller limitation If the value is not set the feature is non enabled and is not used MPF FIRST IN NC A standard gcode NC program file lt name gt prg normally consists of a main program MPF and a series of sub programs SPFs this option allows the MPF to be the first program in the prg file MPF FIRST IN NC 1 or the last program in the prg file MPF FIRST IN NC 0 There are now further options MPF FIRST IN NC 2 then instead for creating lt name gt prg the post processor will create files lt name gt mpf and lt name gt spf with the MPF and SPF data in them as some controllers require the two types of program to be separate MPF FIRST IN NC 3 then instead for creating lt name gt prg the post processor will create files lt name gt mpf and one or more lt name gt xxx spf files where xxx is 001 002 003 etc Thus every program unit is in a separate file This mode can be useful for example on Siemens 840 controllers the SPF s can be accessed directly from the hard drive using EXTCALL without having to load them 42 Cadfil Help 8 53 V7 63 See also the values t
174. s show below SS Be Das Re ed ee plied g Km g cm3 MPa GPa 0 10 6 m mm Tensile Tensile Number of Filament 2 Category Type Descriptive Name Tex Density Strength Modulus Elongation Filaments Diameter Bandwidth 3 Fibre Carbon Toray T300 1000 66 1 76 3630 230 t5 1000 7 1 4 Fibre Carbon Toray T300 3000 198 1 76 3530 230 16 3000 7 1 26 Fibre Carbon Toray MS50JB 6000 216 1 88 4120 475 09 6000 5 1 27 Fibre Carbon Toray M55J 6000 218 1 91 4020 540 0 8 6000 5 1 28 Fibre Carbon Toray M55JB 6000 218 1 91 4020 540 0 8 6000 5 1 29 Fibre Carbon Toray M60JB 3000 103 1 93 3820 588 0 7 3000 5 1 30 Fibre Carbon Toray M60JB 6000 206 1 93 3820 583 0 7 6000 5 1 31 Fibre Carbon Toray M30SC 18000 760 1 73 5490 294 19 18000 5 1 32 33 Fibre Glass Owens Corning Type 30 SE 1200 735 735 2 55 3445 80 48 2000 13 1 34 Fibre Glass Owens Corning Type 30 SE 1200 1100 1100 2 55 3445 72 3 48 2000 17 1 53 Fibre Glass VetroTex Stratifil R Glass RC14 1600 P109 160 1600 2 53 4400 86 5 2 4100 14 1 54 Fibre Glass VetroTex Stratifil R Glass RC14 2400 P109 160 2400 2 53 4400 86 5 2 6200 14 1 56 Fibre Aramid Twaron 2200 805 1 44 2950 99 29 5000 14 1 57 Fibre Aramid Kevlar 29 167 1 44 2920 70 5 3 6 1000 12 1 58 Fibre Aramid Kevlar 49 127 1 44 3000 112 4 24 768 12 1 59 60 Resin Epoxy Sample Epoxy 11 61 Resin Polyester Sample Polyester 1 01 62 Resin Other Sample Resin 0 95 Ral The first two lines are he
175. s the plan to progressively expand this section in the near future 1 11 2 QuckCAD CNG Vessel tutorial 01 If you would like to proceed anyway click See 2 6 1 11 3 Aluminium Bottle QuickCAD Run Cadfil and from the QuickCAD menu select the Dome ended vessel option Fill in the data as shown below Note that non geodesic is ticked as we want to specify both the wind angle on the cylinder and the end opening radius at each end 143 Cadfil Help 8 53 V7 63 QuickCad Cylinder with Dome Ends _ F 2Axis Mode MV Non Geodesic F Joining Path Cylinder Diameter 200 0000 Cancel Cylinder Length fi 100 000 Read Pararn s Shaft Diameter 50 00000 Wind Angle Deg 0 90 fi 2 00000 Wite Params Fibre Band idth 25 00000 Cylinder Clearance 25 00000 Shaft Clearance 25 00000 Help Cylinder Extension Clr fi 20 0000 End Opening Radius x 25 00000 End Opening Radius x 70 00000 Joining Path Stat X CALCULATE Joining Path End x Number of Data Points on Dome f Friction Coefficent 0 2000000 Mandrel Rotation Ditrection 1 fi If you click on help and then Dome ended vessel in the help text you will find a description of the parameters and a diagram link Having entered the data click Write Params this saves your data for if you want to re use or change it later For this example save it as testl par you can re load the data with the Read Params option if required
176. section should not have concave portions as these cannot be wound successfully Low angle winding where the winding paths pass over the mandrel end this is generally required for wind angles less than about 40 degrees 0 degrees being axial The software automatically generates the mandrel geometry See 1 9 18 There are three variants The mandrel has a flat end plate with a pin ring The Mandrel has a idealised end dome this latter option has two variants with different parameters and options that might be applicable to different geometry sections for the mandrel Click See 1 7 10 1 to return to the main topic The windows dialog below is used for the flat mandrel end with a radial pins The winding progresses along the constant section of the mandrel at a constant wind angle the winding goes through pins at mandrel end and when the payout is at the end planes the cross feed moves inwards toward the shaft to the dwell hold radius The fibre is wrapped around the shaft and the the winding proceeds back through the pins to start the next traverse of the mandrel There is usually a considerable build up of material around the shaft to cut away after winding 102 Cadfil Help 8 53 V7 63 Spar Winding mandrel from DXF Mandrel Start 3 Cancel Mandrel Finish X CALCULATE Help Dome length No Dome sections Read Param s Shaft Radius Write Param s Shaft Length Minimum are length around Section End Plane x Pos 1 Extra Dwe
177. sent this option does not check the level of friction that is required to maintain the constant angle and hence if this option is used in an inappropriate manner the fibre path may not be feasible to wind due to slippage Friction checking will be available in a later version of CADFIL Friction Percentage is is the proportion of the friction coefficient to apply The range is 0 to 100 Friction Coefficient is the characteristic value for the fibres resin and mandrel being used A default value is supplied The user will be able to maximise the benefit achievable by using frictionally sustained paths if for each fibre resin system used the maximum coefficient of friction attainable is first determined For example pre impregnated carbon epoxy tape will have a significantly higher friction coefficient when compared to a system of polyester resin wetting out glass fibres pulled through a resin bath The friction coefficient and percentage boxes are only active when LH or RH friction is active via the radio buttons 25 Cadfil Help 8 53 V7 63 Create Delete Step When the path is advanced or retreated across the mandrel surface via left or right mouse clicks respectively on the Cadfil graphics window the number of element segments the path moves is controlled by the step value Clicking the box increases the step and the box decreases the step This can significantly speed the process of path development Fix Point Pressing this butto
178. ser has the choice to enter a new name or to exit from the program When requested for file names a default name is suggested where possible For example if the payout file is TEST PAY then the default for the NC data file would be TEST to create TEST PRG This default can be selected by depressing lt ENTER gt with no other input Alternatively a new name can be entered If the name given for the program file is a file that already exists in the working directory then the user is informed of this and he then has the choice of overwriting the existing file the data in it is then lost or of supplying a new name See 1 6 13 3 1 6 13 3 Entering X datum XDAT This value is used to locate the mandrel along the winding axis from the spindle datum point It is the distance from the spindle datum point a known position on the winding axis to the origin of the mandrel The mandrel origin is the position of the mandrel s zero X co ordinate and lies on the mandrel axis in the mandrel data It is sensible when entering the mandrel data to specify this zero position at a position that is easily identifiable on the mandrel so that measurements can be easily made from it directly It need not be within the mandrel it could be for example on a shaft fixed to the mandrel The XDAT value has a sign This is in the direction of travel of the machine X axis from the spindle datum point to the mandrel origin i e the machine X motion from the
179. ser should note that the band pattern has automatically been calculated in producing the payout file data 1 7 9 Flat Plate Winding 1 7 9 1 Plate Winding The Cadfil plate winding software is a program that generates full numerical control NC data for the winding of flat plate mandrels Organisations working in research and development or in design and quality management often have a requirement to make flat specimens to perform tensile tests flexural tests fatigue tests impacts tests It can be difficult to obtain full design data from tests on standard filament wound samples e g rings and pipes it is also difficult to make true comparisons with composites made from other manufacturing processes The CADFIL Plate software is a ready solution to these problems as it allows an interwoven angle winding onto a rectangular flat plate mandrel Its is possible to produce multi angle wind angle programs comprising of any combination of wind angles For example it would be possible to wind 4 layers of 15 followed by 3 layers of 90 to imitate the fibre layup on a specific filament wound part For the full range of angle combinations the plate mandrel must be such that it has adjustable shafts that allow the winding to be stopped and the plate to be changed over so that it can be rotated it about its other axis A mandrel or mandrel drawings to allow the customer to manufacture a mandrel can be supplied as required Low cost ma
180. sesseseres 115 1 8 8 Post processor error Messages esssessesesesesseressrerererseeesetssereseresseesseessee 117 TO Fig Te Sn e E E EEE E E E RETE TE one 119 1 9 1 Mandrel XR Edit Dialoge BOX sssesssessesesesesseressessresseessserssereseresseesseeesee 119 1 9 2 Graphics Window in Mandrel Envelope X R Edit eeeeeeeeeeeseeeeeneees 119 1 93 Fd XR Data Record ravci uti ee pas ade Ai oe a a Aaa 120 1 9 4 Axisymmetric path Requirements 2 Hoop Points cee eeeeseeeeeeeeeeeeee 120 1 9 5 Winding Angle System For Starting Path eeeeseeeeeeneeeeeeeeseeeees 120 1 9 6 Friction Direction looking on to mandrel surface cesseeeseeeeesteeeeeees 121 BOF Difficult Mandrelss ac satis sic Biabaca e pict alice a iabedaay encores 122 1 9 8 Band Pattern Selection Dialogue s eiscsissietiindusiiiinmnwuunddianiiie 123 1 9 9 Visualisation of fibre B and Patents voisdposapssordsaenatadonaoedansacedcagnanosasananentuanees 123 1 9 10 Band pater ex pl angen reso 6 ein dey see sectredoav a 124 1 9 11 Default Clearance Envelope xizscrav ced acedhos scvacsaateceptocpavecees tated taceavargoeseacatnd 126 1 9 12 The Control CTL file editor cccccccccccccccceessssssseceeececeessssssseeeeeeeees 126 1 9 13 Dome Ended Vessel Parameters 2 2 0ciiccetaceeecsine lati ndienaiies 127 1 9 14 Elbow Winding PArariGters c 95132 ccccssesens gscacseassecuoonsaeedevsaevesapescaeceeearses oe 127 1 9 15 Front amp Back faces of plate with face advance paramete
181. son oa e a e era ae Ragenastyaiintoes 151 230 Side lonen n aia etree cot grt bec E E e e 151 Dd SSM e a ba scare a N A T aE DE A 151 232 MAG Te wasee rnn a E eatin S eee aaa A ove eee 151 Cadfil Help 8 53 V7 63 1 CADFIL Help System 1 1 Getting Started 1 1 1 About Cadfil CADFIL is a registered trade mark of Crescent Consultants Ltd and is protected by Copyright 1986 2011 all rights reserved IMPORTANT Crescent Consultants Limited accepts no liability for loss or consequential loss as a result of use or inability to use the CADFIL software Crescent Consultants Ltd 2 Springfield Kegworth Derby DE74 2DP England Tel 44 0 7958 647196 Fax 44 0 871 263 7797 Email Web 1 1 2 What is Cadfil CADFIL is a computer aided design CAD package for the generation of part programs for interpretation by CNC filament winding machines The aim of CADFIL is to enable the user of the system to easily generate highly accurate CNC part programs for the control of NC filament winding machines Within a few minutes a user can investigate the wind angles possible on a geometry generate a fibre path estimate the amount of fibre required and produce a documented control program complete with estimated wind time CADFIL permits the user to generate programs remote from the winding machine and hence with little or no loss of production winding time The program generated will have been tailored for the optimum band pattern
182. ssor 1 The 5 axes post processor uses all axes except the vertical axis It uses the yaw axis to enable the fibre band to be laid much flatter over the mandrel end It has a disadvantage on most machines that the yaw axis is normally limited in it travel either side of the straight ahead position Thus the yaw axis cannot accommodate low angle wind angles well If the yaw axis is used to take out the fibre twist as in the full 6 axis post processing the machine head needs a large clearance to avoid hiding the mandrel shafts at the mandrel ends The 6 axis post processor is recommended in preference to this one Operation of this post processor is identical to the standard 4 axis post processor Using the correct value of See 1 6 13 4 is essential as when the yaw 48 Cadfil Help 8 53 V7 63 axis is moved there must be compensation in the carriage and cross feed axes if this rotation is not centred about the end of the delivery eye 1 6 8 The 5 axis post procrocessor 2 This uses all axes except the vertical axis This is similar to 5axis option one but the roles of the roll and yaw axes are reversed The yaw axis is used to eliminate twist in the fibre and the roll to take up the wind angle and keep the band central on the payout roller Operation of this post processor is identical to the standard 4 axis post processor Using the correct value of See 1 6 13 4 is essential as when the yaw axis is moved there must be compens
183. t s located relative to the mandrel origin Mouself an approximate start location on the mandrel is satisfactory then the user can move the mouse cursor to the desired position and click the left mouse button RadiuslIf a specific end opening is required this option can be used refer to the following section entitled See 1 3 7 required Once the start position is specified the start angle can be specified from the following options HOOP UHOOP Up is used to start the fibre path in the hoop direction 90 degree winding angle If this option is used one hoop point is now already generated and if the location is on the mandrel end the opening diameter has thus been fixed HOOP DHOOP Down is that same as HOOP U except that the fibre starts with 90 degree winding angle The direction of rotation of the mandrel in the winding machine will be opposite to using hoop up CURSORThis option displays a cursor cross at the position where the fibre start position was previously requested Using the mouse the user stretches the rubber band line to make the angle required between the band line and the horizontal Once the approximate angle has been achieved the user left clicks ANGLEA dialogue box requests the start angle to be input displaying ENTER START ANGLE 180 The user is required to input the start angle See 1 9 5 Once the fibre start position and angle has been specified the software proceeds to the See 1 3 10 descr
184. t Process Menu This consists of a sequence of payout files that the user has generated for winding different angles and See 1 3 14 to wind from the end of one layer to the start of the next When the user later selects a post process option it will ask for a payout pay name If lt name gt ctl exists it will read this control file instead for looking for a payout file It will thus process all the payout files in the control file The control file editor consists of an easy to use dialogue The options are OPENthis option asks for the file name of and existing control file These have the CTL file name extension The file is loaded and the data displayed ADDthis option allows the user to add a new line of data A dialogue box pops up show all the payout files available and the user can select one The system then asks for the number of times to repeat the program i e the number of layers and the position in the 37 Cadfil Help 8 53 V7 63 winding sequence list The position number of existing items in the list is displayed on screen in the control edit dialogue DELETEthe user clicks on a line of data this will highlight it and then clicks on the delete button to remove the line FINISHthe user is asked to enter a name for the control file to save the data to The user can overwrite update the file read in or create a new file 1 6 Post Processing 1 6 1 Introduction to Post Processing The function of the post proc
185. t cylinder 0 0X coord of centre of end 1 10 0Y coord of centre of end 1 25 0Z coord of centre of end 1 0 0X coord of centre of end 2 10 0Y coord of centre of end 2 25 0Z coord of centre of end 2 10 0Radius of cylinder 25Number of points around second cylinder 0 0 15 0 0 0 0 0 115 0 0 0 5 0 25 0 0 110 0 0 0 134 Cadfil Help 8 53 V7 63 0 0 120 0 0 0 20 0 The geometry should be fixed such that fibre dispense point of the head should be at coord 0 0 0 The B motion eye roll rotation is a rotation about the block definition Y axis and the yaw C motion is about the Z axis The rotation centre in both cases being 0 0 0 There is a limit to the number of points allowed in a block definition Each cylinder uses Number of points 6 points A total of 500 points must not be exceeded for all cylinders an error will be given if it is More points per cylinder gives a better resolution for shading but drawing will be slower 1 10 2 3 Material cnf The MATERIAL DATA FILE MATERIAL CNF supplies the system with the default material values that are to be used These values can be entered during a system run but if the user uses a different set of material data regularly then the material data file can be modified An example of the file is given below along with the necessary format of the file required The user can create is own lt name gt cnf files an the software will allow him to choose which to
186. t initialised by Cadfil 10 11 13 14 15 Only for DK12 parallel key DK12 is now obsolete 12 Cadfil version number too high for licence data version The above are the ones that you might see The DK12 datakey is obsolete at Cadfil Version7 25 The error codes when installing a new licence file are different meanings these are 1 Lic dat file selected is not found 2 Error opening lic dat file 3 Error reading lic dat file 19 Lic dat file is corrupt 5 6 License file is time expired 7 DK3 found but not recognised 8 Wrong DK3 for licence file wrong licence file for DK3 9 11 12 DK12 error codes 1 10 2 Appendix A Cadfil file formats 1 10 2 1 Configuration files CADFIL has a number of configuration files lt config gt SMContains configuration of winding machine and default values for the post processor MATERIAL CNFContains data relating to material used for filament winding PAYHED BLKContains a geometric description of the fibre dispensing head for simulation When CADFIL is run it will look in the current working directory if any of these files are not found an error message will be given 133 Cadfil Help 8 53 V7 63 1 10 2 2 Payhed blk file The user can define a fibre delivery head geometry for use in the 3D visualisation The head is a solid defined from cylindrical primitives An example of such a file is shown below Number of cylinders ONumber of brick elements 25Number of points around firs
187. t internally It is also possible to use LEN_UNIT_NAME INCH in the sm file This is mainly used in output e g speed graphs for information however some internal constants are converted from mm to inch is inch is set The mandrel should always be defined in the units selected The Time unit is for information in outputs only Actual speed values feed rates must match the units actually used by the controller In the SM file you can set TIME_UNIT_NAME or TIME_UNIT_NAME Minute Minute is set by default Winding speed This is set in one of the dialogue text windows For most machines this will have units of mm min The default value is the start feed from the SM file This winding speed is used in different ways depending upon the feed option selected For option 0 the value entered is the value that will be specified at the top of the NC sub program For option 1 this will be the speed of the mandrel axis Exceptionally on a few customer configurations this is the mandrel surface speed at the largest mandrel diameter For options 2 and 3 the feed rate is calculated such that the combined feed to the relevant axes is equal to the value entered Total feed for a set of axes is usually calculated by summing the squares of the incremental motions on each axis and then taking the square root SO distance V a b c where a b and c are the incremental motions on an NC line for mandrel carriage and cross feed axes 54 Cadf
188. t main data point If this is the last point then the fit radius is ignored The extra points are a number of X R data points that are automatically created on the fit radius If the fit radius is zero the extra points are created on a straight line If the extra points value is zero then the fit radius is ignored If fit radius is negative then the radius will be concave rather than convex Clicking on a line of data allows the values to be edited via a popup edit box_shown below XR Record Edit x R Extra Points Fit Radius 503 090 95 106 0 0 000 Add Data Button This option See 1 9 3 where the user can enter the four values X R Additional points and Fit radius These data are then added to the mandrel or envelope Delete Data Button 14 Cadfil Help 8 53 V7 63 The pops an edit box asking for the data point numbers to delete The user can enter multiple points e g 1 3 5 Would delete points 1 3 and 5 Up to five lines of data can be deleted in one go Flip Button The options turns the mandrel around for example if this part was a gas cylinder the neck would go from the X end to the X end or visa versa Datum Button This options allows the user to add a value it may be negative to all mandrel positions to move its origin zero position Scale Button This options allows the user to multiply all values by a scale factor So for example if the data was entered in inches but mm are required then enter a scale
189. t processor has finished a summary of the maximum feed rates for each axis for each sub program file SPF is given This looks like the picture shown below 55 Cadfil Help 8 53 V7 63 FEED RATE SUMMARY Axis Speeds for each layer es a of maxiumum speed for the axis Axis names are as the in the SM file If there is only one SPF then only one layer will be shown that is only one line of data The titles across the top show the names that were assigned to the machine axes in the winding machine configuration file SM file The values in the table show the maximum speed that each axis has at some point in that SPF The speed is expressed as percentage of the maximum speed defined for that axis as shown in the NC See 1 9 17 The default speed maximum values are set in the SM file So for layer 3 above the X axis has a maxim value of 13 3 whilst the Y axis has a maximum of 25 3 Is should be noted that any axis showing 100 indicates that the axis was requested to go over speed and has been limited to the maximum value in the interests of safety There is a very important point here if for example the user has a large and heavy mandrel the constant mandrel speed feed rate option might be chosen so as not to over stress the machine If in this case an axis has been limited at 100 then the constant mandrel speed will not have been achieved the axes will all have been slowed at the points where over speed would have
190. tered when the 6 axis transformation angle is requested The default value is 45 degrees Using this option radial mandrel clearance can be optimised for example if the Z travel is 300mm And the Y travel is 600mm from the mandrel centre line the angle would be optimal at arctan 300 600 and the maximum radial clearance would be 600743007 The standard 6 axis system should usually be used in preference to this option 1 6 12 Transfer NC to Winder Cadfil currently does not include any transfer software for communication between the PC and the NC controller on the winding machine This transfer is often proprietary to the CNC in question If transfer software is provided by the controller manufacturer this can be integrated so that it can be launched from the NC Post Process Menu On the Transfer NC to Winder Option This option is controlled by three variables in the See 1 6 2 These are 50 Cadfil Help 8 53 V7 63 NC TRANSFER MODE This takes values of 0 for no transfer to winder option or 2 for transfer to winder using an external program 1 is intended for a CADFIL internal transfer option but this is not currently avialable The path and name of external transfer program is specified as in the example below NC TRANSFER PRG A third option allows command line parameters for external transfer program if this are needed If they are not needed do not set this value NC TRANSFER CMD LN p n The transfer to winder can also
191. than 180 degrees should be divided into sections that are less than 180 degrees b The axis of the mandrel should be the World Z axis i e through point 0 0 the mandrel is assumed to rotate about this axis c The Lines and arcs for the mandrel MUST be joined to form a closed polyline or lwpolyline use the AutoCAD Pedit or PE command d This polyline must be on a layer called SEC and this layer should contain only one polyline but can contain other data Note when CADFIL reads the dxf file only the first 3 letters of the layer name are considered so if the DXF file has layers multiple layers starting with SEC e g SEC1 SEC22 then unpredictable results or errors may occur e A clearance envelope for creating the payout path can also be created in the DXF file The rules for creating the envelope are exactly the same as for the mandrel cross section except that the polyline for the envelope must be on a layer called SNV In some versions of AutoCAD it is possible to offset a polyline using the OFFSET command Thus having created a polyline for the mandrel section the envelope can be created with an all round constant clearance by offsetting it outwards and then moving the new polyline to the SNV layer Again only the Cadfil has been tested on AutoCAD R12 R13 R14 amp 2000 2006 and 2008 DXF files 98 Cadfil Help 8 53 V7 63 POLYLINE layer SNV POLYLINE layer SEC A ORIGIN 0 0 l 1 7 10 3 High Angle Winding Param
192. the 3D machine path payout path is described After saving a fibre path you can proceed to the Create Payout Path option when prompted Alternative a payout path PAY files can be created from a FIB file at any time by using the Create Payout Path option from the Cadfil Main menu The steps are simple 1 Selected the Create Payout Path option from the Cadfil Main menu 84 Cadfil Help 8 53 V7 63 2 Selected a fibre path FIB to process 3 Some filtering of the paths data is then undertaken this does two things it deactivates data points that are very close together the tolerance is set automatically based on the mandrel size parameters and is eliminates any points around the tee blend where there is liftoff bridging Such point cause the mandrel motion to be erratic Please note where liftoff is indicated the fibres will not be tight to the mandrel surface and may require some consolidation after winding The view below indicates where lift off points have been identified WF ie XP Wee ie Boh NT I W BONS Pixs Se r N a LX je 4 H RA ANY aa Ne A A A i Te aan i lir T N i A htt fh UA V y XZN AN vais ZEN SLT iR WY l ZH Click OK to continue The path will be check again and some additional points may be found Keep clicking OK
193. the data entry box for this is made avialable In this case the winding is geodesic on the cylinder and non geodesic on the domes A mandrel file and a payout file for viewing and subsequent post processing is automatically created The mandrel file can be used in the standard Cadfil Axsym program to create joining paths for wind paths created by the dome program The parameters are See 1 9 13 71 Cadfil Help 8 53 V7 63 Two axis check box Tick this box if winding machine only has two axes Mandrel AX1 Carriage AX4 or if you only want to use two axes The shaft and cylinder extension clearance are not needed and are greyed out if you select this option Non Geodesic Check Box if available Tick this box for non geodesic winding on the end domes The end opening radius can then be specified at each end Please note that this end opening radius makes allowance automatically for the width of the fibre band entered and so is the true end opening Joining Path Check Box if available Tick this box to create a path to join two programs together The user must specify the start and finish positions along the mandrel Some of the variables below will not be required and will be greyed out Cylinder Diameter 2xR1 The is the diameter of the cylindrical part of the mandrel and hence of the spherical dome Cylinder Length L The length of the cylinder between domes Shaft Diameter The diameter of the end shaft s
194. tion zone from ED to EOD is conical with an arbitrary gradient of 4 76 degrees 1 7 7 2 Tees Template Path Creation This section details creating an initial template path for winding Pipe Tees An overview of the whole process can be found in the main See 1 7 7 1 The template path option can be selected from the The Tee Dialog Make Template Path option But this is a link to the Cadfil Main Menu Fibre Path Create Option that is discussed elsewhere in this help file The Topics See 1 3 6 The See 1 3 10 See 1 3 11 and the See 1 3 13 are all relevant T Winding c T Mandrel Generate Cancel Make Template Path Reflect Path X 0 Reflect Path Y 0 Help Parallel Path Convert Pipe Payfile The steps are 1 Pick the name of the Tee mandrel that is to be used The Tee mandrel should already have been created using the See 1 7 7 1 option 2 Set the start position using the By mouse click option This is currently the only option relevant to Tees Click near a point on the symmetry plane Y 0 of the mandrel A line should then be highlighted as below For reference the X axis of the tee is the winding rotation axis along the cross piece The Z axis is along the axis of the leg and the Y axis is orthogonal to both forming a right handed set The Origin 0 0 0 of the Tee as at the point of intersection of the 2 pipe axes 81 Cadfil Help 8 53 V7 63 EzF LEG i Cadfil Message
195. too small test winding will be worrying Also on some machines there may be small positional errors as the winding speed is increased so beware 12 Cadfil Help 8 53 V7 63 The programmed position is for the centre of the dispensing eye or roller If this has a large width this must be reflected in the envelope or a crash may occur on the corners at the mandrel ends when moving in It is best not to have too many points or a more complex envelope than is necessary Cadfil will automatically create a default envelope if the user does not create one This may not be always be ideal it is best to check Mandrel and envelope data can be created by See 1 2 3 created in a CAD system such as AutoCAD this is described in the following section 1 2 2 Mandrel X R Edit Creating mandrel or envelope data for axisymmetric shapes is done performed using the XR Data Entry Dialogue Box the features of this dialogue box are described below Mandrel X R Data Entry symmetry V Point Labels End Symmetry Y Draw Expanded Envelope Data End Symmetry Mandrel Data POINTS RADIUS Flip X Datum OK Add Data Delete Data Help Click on line of data to edit Point Labels Check Box If this box is checked numbers are placed on the data points on the See 1 9 2 These numbers match the point numbers in the mandrel or envelope data list If the Draw Expanded option is checked the additional points are shown so the point n
196. ts to be further away in length from the mandrel centre the machine will then move on a circular plane at the end of the envelope This determines the furthest distance away the cross feed axis will be from the winding axis Bandwidth BWID This is the width of the fibre band to be used and is saved associated with parameters in the mandrel data Once entered the Write Params option can be used to save the parameter data for example to the file name par This can be read back later using Read PArams if there is a need to change the data The calculate button is clicked then to generate the mandrel data You will be asked to give a name for the mandrel file this will be saved with the mnd extension for example mytee mnd After some calcualtion you will be asked for the mandrel name again it is best to use same name as the initial mandrel data has been processed further and is now not needed Envelope Branch Outer Diameter EOD 80 Cadfil Help 8 53 V7 63 The leg usually requires quite a large clearance diameter ED to allow for the width of the payout eye For this reason the outer end of the POE needs to be as narrow as possible to allow a smaller clearance The branch cylinder has the same clearance diameter ED around the intersection area however outside this area a smaller clearance can be used EOD this should be as small as is practical to stop excess program motion that can lead to a loss of fibre tension The transi
197. umbers may not match the data list Draw Expanded Check Box Mandrel or envelope data consists of basic data point and additional points that tie on lines or circular arcs between basic data points if Draw Expanded is checked this additional points are shown on the mandrel envelope drawing in the graphics window 13 Cadfil Help 8 53 V7 63 No Symmetry X End Symmetry X end Symmetry Buttons These buttons set symmetry options The options are X END to set a flag to say the mandrel and envelope is symmetric about the left hand X data position of the mandrel X END to set symmetry about the right hand end or NONE the normal option Note that for X symmetry the envelope must not have points with X values greater than the largest mandrel X position and for X symmetry the envelope should not have X co ordinates less than the smallest mandrel X position Mandrel Data Envelope Data Buttons When these button are clicked the focus switches from editing Mandrel data to Envelope data Or visa versa and the data in the Text Data List box also switches Text Data List Box See 1 9 1 shows 5 entries for each mandrel or envelope as selected with the Mandrel Data Envelope Data Buttons These are a point number see Point Labels and X position a Radial R position Extra Points and Fit Radius The X amp R positions are main data x y points for the mandrel profile The fit Radius is a circular arc to fit between this point and the nex
198. us R1 Right End Cap Cylinder Length L Machine Clearance Envelope Cylinder Clearance C1 Axial Clearance C2 Left Shaft Clearance Right Shaft Clearance Te SR SL SR S 1 X BE i 7 Bai in ome na 1 9 14 Elbow Winding Parameters Mandrel Origin Mandrel Radius Wind axis Bend Angle eA Bend Radius y ELBOW WINDING PARAMETERS 127 Cadfil Help 8 53 V7 63 1 9 15 Front amp Back faces of plate with face advance parameter 2 O 1 9 16 Front amp Back faces of plate with face advance parameter 1 ANA 128 Cadfil Help 8 53 V7 63 1 9 17 NC Feedrate Dialogue NC Speed Calculation eae B F value On Mandrel Carriage z m Description Name Maximum Speeds Maximum Accelerations NC Start SpeediFeed Rate 1 Mandrel A 43000 00 100000 0 1000 000 2 Eye Roll j B j 60000 00 100000 0 3 100000 0 NC Winding SpeediFeed Rate 3 EyeYaw E 0000 00 4 Carriage x j 60000 00 100000 0 15000 00 5 Cross Feed 30000 00 100000 0 6 Vertical Z 30000 00 100000 0 Help LengthUnt MM CS Use Mandrel Surface Speed Rotation Unit DEGREES Surface Speed 60000 00 Time Unit MINUTES S437 747 I Mandrel Max Feed 1 9 18 Spar winding Parameters MANDREL SECTION DEFINED IN DXF FILE CLEARANCE ENVELOPE DEFINED IN DXF FILE Ssnl
199. use during payout path creation The user could create a separate file e g Eglass cnf 12Kcarbon cnf etc for each material type used 0 100Coefficient of friction 1 10Default Resin Density 2 56Default Fibre Density 2400 Default Fibre Tex Mass per Unit Length 4Default Number of Rovings 1000 0Default Thickness equation constant 0 60Default Ratio for fraction of fibre by mass 12 0Default Filter Angle 0 20 Degree range 100 0Default Filter Length 50 0Default Payout Eye Clearance 135 Cadfil Help 8 53 V7 63 10 Default fibre band width All the information must be on separate lines These are read in FORTRAN FREE format 1 10 2 4 Fibre path file FIB The fibre design section generates files with a FIB extension These files contain data relating to how the fibre file was generated along with the fibre path co ordinate and direction data 16 REVIEW MND 24 55 1 44 5395 0000 75 8139 0000000 1 0000000 0000000 2 43 4120 19 7904 73 8587 0566083 9935595 0981583 3 39 8676 39 2541 67 9901 1688622 9431811 2861730 4 33 5750 58 0798 58 0798 2782439 8483473 4504291 5 23 8938 75 9680 43 8602 3828931 7200355 5787416 6 9 7015 92 6372 24 8221 4810300 5726655 6638254 30 0000 99 7655 13 1751 5709853 4219989 7041962 55 10 0733 101 5000 0000 6577299 0983193 7468095 The data contained within the file has the structure as outlined below Integer identifier usually 16 Line Format 1X

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