Finite element simulation of the braiding process for arbitrary mandrel shapes

An approach to simulate the two-dimensional braiding process using a commercial explicit finite element software is presented. Preforms with generic shapes are analyzed. A procedure is given to determine the boundary conditions of the braiding mandrel including the extraction of necessary geometry information. The friction coefficients needed as input parameters are determined in separate tests. The simulation results are processed with an algorithm that derives the braiding angle and the axial spacing of the yarns. For validation, a generic mandrel geometry is overbraided and a method to compare simulation and experiment is presented. The preform is analyzed using an optical sensor. The measurements are filtered and averaged. The simulation model is validated by comparing the braiding angle of simulation and experiment. A good agreement between simulation and experimental results is achieved.