Three-dimensional braided composite materials are widely used in special-shaped structural parts in aviation

aerospace

military and other fields

but in order to ensure the quality of structural parts

it is necessary to carry out multiple trial productions to verify the effectiveness of the braiding process

which brings high costs. To address the challenges of high validation costs and prolonged optimization cycles in braiding parameter verification

this study proposed a universal simulation approach for special-shaped braided structures based on model reconstruction algorithms. Firstly

the centerline of the mandrel of the special-shaped structural parts was extracted based on the model data

and the key sections of the mandrel were regenerated based on the model outline

and the mesh of the model was reconstructed. Secondly

based on the kinematic characteristics

the fabric trajectory on the surface of the mandrel was generated

the interweaving relationship of the braiding process was analysed

the yarn trajectory was optimized

and the spatial topology and fabric structure model of the preform were generated. Finally

according to the braiding experiment

the accuracy of the method proposed in this paper is verified

and the error at the variable cross-section and variable curvature is not more than 5°. This innovative approach demonstrated strong compatibility with CAE integration platforms for braiding equipment

offering an efficient digital verification solution for composite manufacturing processes.