Simulation technology for braiding process of composite materials based on kinematic principles

doi:10.11996/JG.j.2095-302X.2025051061

Abstract

Abstract:

A simulation algorithm for the braiding process of composite materials is presented, specifically addressing the calculation and prediction of braiding machine control parameters, yarn trajectories, and braid angles. The algorithm operates through two complementary subprocesses: inverse solution generates machine control data based on target braid structures, while forward solution computes yarn trajectories and braid angle distributions using predefined control parameters. Initially, the surface of the mandrel is discretized into a set of triangular patches as program inputs. The mandrel centerline is extracted, and local solutions are performed according to kinematic principles. The inverse solution algorithm generates the braid structure of the preset braid angle and determines the corresponding take-up speed, while the forward solution algorithm calculates the yarn trajectories and braid angle distribution of specific take-up speed and control parameters. The BraidSim module, developed on the FreeCAD platform, integrates functionalities including mandrel surface meshing, trajectory generation, and dynamic yarn deposition simulation. The proposed algorithm has been validated through typical braiding cases including circular variable cross-section mandrel, square variable cross-section mandrel, aero-engine intake mandrel and spatial curve mandrel. Results demonstrate that the obtained take-up speed and braid angle distributions align closely with design expectations. Additional simulations are conducted for variable cross-section mandrel and curved centerline mandrel, generating corresponding inverse solution machine control data and forward solution braid angle distribution, demonstrating the applicability of the algorithm to complex mandrels.

Key words: composite material manufacturing, two-dimensional triaxial fabric, virtual simulation, FreeCAD, software design

CLC Number:

WU Haoyu, YANG Xiaochao, WANG Wei, ZHAO Gang. Simulation technology for braiding process of composite materials based on kinematic principles[J]. Journal of Graphics, 2025, 46(5): 1061-1071.

Figures/Tables 17

Fig. 1 Braid machine

Fig. 2 Typical two-dimensional triaxially braided composites

Fig. 3 Definition of the braid angle[28]

Fig. 4 Calculation of desired trajectory drop point

Fig. 5 Expected trajectory

Fig. 6 Valid drop point

Fig. 7 Illustration of braiding parameters

Fig. 8 Braiding parameter solving process

Fig. 9 Guide ring contact check ((a) No contact; (b) Contact)

Fig. 10 Illustration of yarn stacking

Fig. 11 Key software library in FreeCAD

Fig. 12 Braiding model generating interface

Fig. 13 Demonstration of the simulation process

Fig. 14 Simulation result of circular mandrel with variable section ((a) Expected trajectory; (b) Braiding speed; (c) Yarn trajectory; (d) Distribution of braid angle)

Fig. 15 Simulation result of rectangular mandrel with variable section ((a) Expected trajectory; (b) Braiding speed; (c) Yarn trajectory; (d) Distribution of braid angle)

Fig. 16 Simulation result of aero-engine inlet mandrel with variable section ((a) Expected trajectory; (b) Yarn trajectory; (c) Distribution of braid angle)

Fig. 17 Simulation result of curved mandrel with variable section ((a) Expected trajectory; (b) Yarn trajectory; (c) Distribution of braid angle)

References 31

[1]	王士心, 许可. 稀疏监测样本下的复合材料固化过程热源分布动态估计[J]. 图学学报, 2024, 45(2): 388-398. DOI
	WANG S X, XU K. Dynamic estimation of heat source distribution during solidification of composite materials under sparse monitoring samples[J]. Journal of Graphics, 2024, 45(2): 388-398 (in Chinese). DOI
[2]	云峰, 王有治, 宋娇, 等. 增材制造自支撑点阵-实体复合结构拓扑优化方法[J]. 图学学报, 2023, 44(5): 1013-1020. DOI
	YUN F, WANG Y Z, SONG J, et al. A lattice-solid hybrid structure topology optimization method for support-free additive manufacturing[J]. Journal of Graphics, 2023, 44(5): 1013-1020 (in Chinese). DOI
[3]	吴振华, 赵韩, 董玉德, 等. 基于梯度有限元的异质材料实体优化设计[J]. 图学学报, 2012, 33(6): 76-81.
	WU Z H, ZHAO H, DONG Y D, et al. Optimal design of heterogeneous objects based on graded finite elements[J]. Journal of Graphics, 2012, 33(6): 76-81 (in Chinese).
[4]	张建宝, 赵文宇, 王俊锋, 等. 复合材料自动铺放工艺技术研究现状[J]. 航空制造技术, 2014(16): 80-83, 94.
	ZHANG J B, ZHAO W Y, WANG J F, et al. Research status of automated placement processing technology of composites[J]. Aeronautical Manufacturing Technology, 2014(16): 80-83, 94 (in Chinese).
[5]	GHAEDSHARAF M, BRUNEL J E, LEBEL L L. Multiscale numerical simulation of the forming process of biaxial braids during thermoplastic braid-trusion: predicting 3D and internal geometry and fiber orientation distribution[J]. Composites Part A: Applied Science and Manufacturing, 2021, 150: 106637.
[6]	VAN RAVENHORST J H, AKKERMAN R. Overbraiding simulation[M]// KYOSEVY. Advances in braiding technology:specialized techniques and applications. Oxford: Woodhead Publishing, 2016: 431-455.
[7]	PICKETT A, ERBER A, VON REDEN T, et al. Comparison of analytical and finite element simulation of 2D braiding[J]. Plastics, Rubber and Composites, 2009, 38(9/10): 387-395.
[8]	BOHLER P, PICKETT A, MIDDENDORF P. Finite element method (FEM) modeling of overbraiding[M]//KYOSEV Y. Advances in braiding technology:specialized techniques and applications. Oxford: Woodhead Publishing, 2016: 457-475.
[9]	PICKETT A K, SIRTAUTAS J, ERBER A. Braiding simulation and prediction of mechanical properties[J]. Applied Composite Materials, 2009, 16(6): 345-364.
[10]	VU A N, GROUVE W J B, WARNET L L, et al. Modeling anisotropic friction in triaxial overbraiding simulations[J]. Composites Part A: Applied Science and Manufacturing, 2024, 177: 107958.
[11]	VU A N, GROUVE W J B, DE ROOIJ M B, et al. A mesoscopic model for inter-yarn friction[J]. Composites Part A: Applied Science and Manufacturing, 2024, 180: 108070.
[12]	CZICHOS R, BAREIRO O, PICKETT A K, et al. Experimental and numerical studies of process variabilities in biaxial carbon fiber braids[J]. International Journal of Material Forming, 2021, 14(1): 39-54.
[13]	LU X Y, BO P B, WANG L Q. Real-time 3D topological braiding simulation with penetration-free guarantee[J]. Computer-Aided Design, 2023, 164: 103594.
[14]	LI Z J, DAI H L, LIU Z G, et al. Micro-CT based parametric modeling and damage analysis of three-dimensional rotary-five-directional braided composites under tensile load[J]. Composite Structures, 2023, 309: 116734.
[15]	MICHAELI W, ROSENBAUM U, JEHRKE M. Processing strategy for braiding of complex-shaped parts based on a mathematical process description[J]. Composites Manufacturing, 1990, 1(4): 243-251.
[16]	DU G W, POPPER P. Analysis of a circular braiding process for complex shapes[J]. The Journal of the Textile Institute, 1994, 85(3): 316-337.
[17]	KESSELS J F A, AKKERMAN R. Prediction of the yarn trajectories on complex braided preforms[J]. Composites Part A: Applied Science and Manufacturing, 2002, 33(8): 1073-1081.
[18]	LONG A C. Process modelling for liquid moulding of braided preforms[J]. Composites Part A: Applied Science and Manufacturing, 2001, 32(7): 941-953.
[19]	FOULADI A, NEDOUSHAN R J. Prediction and optimization of yarn path in braiding of mandrels with flat faces[J]. Journal of Composite Materials, 2018, 52(5): 581-592.
[20]	MONNOT P, LÉVESQUE J, LEBEL L L. Automated braiding of a complex aircraft fuselage frame using a non-circular braiding model[J]. Composites Part A: Applied Science and Manufacturing, 2017, 102: 48-63.
[21]	VAN RAVENHORST J H, AKKERMAN R. A yarn interaction model for circular braiding[J]. Composites Part A: Applied Science and Manufacturing, 2016, 81: 254-263.
[22]	WU Z Y, SHU Z X, KYOSEV Y, et al. Numerical prediction methodology for tow orientation on irregular mandrels with constant cross-sections[J]. Journal of Composite Materials, 2019, 53(8): 1067-1078.
[23]	GONDRAN M, ABDIN Y, GENDREAU Y, et al. Automated braiding of non-axisymmetric structures using an iterative inverse solution with angle control[J]. Composites Part A: Applied Science and Manufacturing, 2021, 143: 106288.
[24]	HANS T, CICHOSZ J, BRAND M, et al. Finite element simulation of the braiding process for arbitrary mandrel shapes[J]. Composites Part A: Applied Science and Manufacturing, 2015, 77: 124-132.
[25]	HEIECK F, HERMANN F, MIDDENDORF P, et al. Influence of the cover factor of 2D biaxial and triaxial braided carbon composites on their in-plane mechanical properties[J]. Composite Structures, 2017, 163: 114-122.
[26]	WEHRKAMP-RICHTER T, HINTERHÖLZL R, PINHO S T. Damage and failure of triaxial braided composites under multi-axial stress states[J]. Composites Science and Technology, 2017, 150: 32-44.
[27]	SWERY E E, HANS T, BULTEZ M, et al. Complete simulation process chain for the manufacturing of braided composite parts[J]. Composites Part A: Applied Science and Manufacturing, 2017, 102: 378-390.
[28]	VAN RAVENHORST J H. Design tools for circular overbraiding of complex mandrels[D]. Enschede: University of Twente, 2018.
[29]	ARGYRIS J. An excursion into large rotations[J]. Computer Methods in Applied Mechanics and Engineering, 1982, 32(1/3): 85-155.
[30]	BJÖRCK Å. Numerics of gram-schmidt orthogonalization[J]. Linear Algebra and its Applications, 1994, 197-198: 297-316.
[31]	VAN RAVENHORST J H, AKKERMAN R. Circular braiding take-up speed generation using inverse kinematics[J]. Composites Part A: Applied Science and Manufacturing, 2014, 64: 147-158.