Design of fast braiding process based on reconstructing mesh with complex and irregular mandrels

Abstract

Circular braiding of large-sized and complex irregular structural components is widely used in fields such as aerospace and rail transit. However, existing braiding process design and simulation algorithms lack applicability to mandrels with complex features, such as flanges, concave corners, holes, and hollows, which also have low calculation efficiency in the braiding process simulation. This study first proposes an optimization algorithm for the complex features on the mandrel surface, improving the applicability for the braiding process design of complex and irregular mandrels. Then the mandrel mesh was reconstructed, greatly improving the computational efficiency of the braiding process design process. Finally, a fast iteration method based on the mandrel reconstructed mesh was proposed to achieve the fast calculation of process control parameters, including traction trajectory and traction speed, as well as the prediction of forming quality for the braiding angle and coverage rate. The experiment shows that the algorithm improves the applicability of the multi-braiding angle process and shortens the sampling cycle of braiding process design by more than 60%.