Production Engineering

, Volume 13, Issue 5, pp 519–528 | Cite as

Modeling and optimization of winding paths to join lightweight profiles with continuous carbon fibers

  • Marius DackweilerEmail author
  • Tobias Mayer
  • Sven Coutandin
  • Jürgen Fleischer
Computer Aided Engineering


A major challenge in composite manufacturing is to connect several fiber composite or hybrid profiles to a closed structure, since the conventional, metallic joining methods are often not applicable. An approach for joining such profiles is represented by the filament winding process, where the profiles are wrapped with carbon fibers. In order to achieve a flexibility in the joining process and a high reproducibility in deposition, a model for describing the winding paths was derived. An analytical model of the geometry of a T-joint is introduced in terms of a mathematical parametrization of areas. For the modeling of the winding paths itself, a differential-geometric approach combined with an algorithm to calculate geodesic and non-geodesic curves was used taking into account the relevant influencing parameters during winding. This model makes it possible to map different winding patterns of the profiles, which should serve as a starting basis for a kinematic simulation of the movements.


Filament winding Process modeling Automation Joining 

List of symbols

ψ, χ

Parameters to describe the longitudinal profile (–)


Length of longitudinal profile (mm)


Profile radius (mm)


Inclination angle (°)


Complementary angle to cross profile inclination (°)

r1, r2

Radii of flanges (mm)

α1, α2

Connection angles of the partial flanges (°)

Rgross1, Rgross2

Inclination flange surface to vertical (mm)


Maximum large radii of the underlying torus (mm)

b1, b2

Wall thickness of the flange (mm)


Distance from upper edge of fillets to center of inclination (mm)

ξ, z

Length of cross profile (–)

φ, θ

Parameters for describing the cross profile (–)


Parameter describing the flange (mm)

a0, a1, a2

Minimum large radius of the underlying torus


Angle between curve and surface normal (°)


Normal vector (–)


Tangential vector (–)


Distance (–)


Slipping tendenc zy (–)


Curvature (–)


Geodetic curvature (–)


Normal curvature (–)


Slipping coefficient (–)



This work was supported by the German Research Foundation (DFG: Deutsche Forschungsgemeinschaft, Project-No.: 397377132).


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Copyright information

© German Academic Society for Production Engineering (WGP) 2019

Authors and Affiliations

  • Marius Dackweiler
    • 1
    Email author
  • Tobias Mayer
    • 1
  • Sven Coutandin
    • 1
  • Jürgen Fleischer
    • 1
  1. 1.wbk Institute of Production ScienceKarlsruhe Institute of TechnologyKarlsruheGermany

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