Finite element simulation of the braiding process

S Del Rosso,P.T Curtis,L Iannucci

doi:10.1186/s40759-019-0041-4

S Del Rosso, P.T Curtis + Show 1 more

Open Access

https://doi.org/10.1186/s40759-019-0041-4

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Abstract

Braiding is one of the most common technique employed for the manufacture of fabrics and ropes. It is also commonly used to produce near-net shaped preforms for advanced fibre reinforced composites. This paper presents an explicit finite element approach to create and simulate the braiding process for the virtual manufacture of 2D braids. The process starts from the definition of an analytical function which describes the movement of the carriers on a braiding track plate. Models of idealised Maypole-type braiding machines are built and used to shape virtual yarns into braids. This procedure can be used in a parameter control fashion, to optimise or to create virtual braided structures, which can serve as input for other structural analyses. It is emphasised that multiple cylinders are required for the modelling of a multifilament yarn to achieve better correlation with the experimental results. A parametric study is presented to investigate the effect of the number of virtual cylinders to represent a real yarn and the shape of the final braid. Excellent correlation was found between the virtual models and the experimental results when comparing the braid angle and yarn width.

Highlights

Computer simulations have been extensively used in engineering manufacture to understand each phase of the production and design process
This study has shown that the Finite Element technique can be successfully applied to replicate the braiding process for the creation of virtual braids
The proposed method can be implemented to replicate the behaviour of any Maypole type braiding machine for the manufacture of braids of different architectures, number of braided threads and braid patterns

Summary

Introduction

Computer simulations have been extensively used in engineering manufacture to understand each phase of the production and design process. Process simulations can be used to replace costly trial-and-error and product development steps to produce parts with optimal design, and tailored physical and mechanical properties. Many industrial processes, such as injection moulding, forming, stamping, welding, additive manufacturing, as well as automation and robotics rely on computer simulations (Radi and Hami 2016; Salvendy 2001). The so called FE method can be used to create and simulate the physical braiding process It can be used as an optimisation tool to determine the best braid geometry to fulfil the mechanical requirements in specific engineering applications

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