An integrated approach toward digital design and simulation of the automated overbraiding process for composite manufacturing

The study presents a new integrated hybrid modeling framework that combines kinematic models with Finite Element Analysis (FEA) to simulate the overbraiding process on non-circular and variable cross-section mandrels in composite manufacturing. By combining the computational efficiencies of kinematic models with the detailed physical insights from FEA simulations, this hybrid method provides a holistic solution for designing and prototyping overbraided structures. Specifically applied to a complex rectangular-to-square mandrel, the approach accurately predicts braid angles, validated against physical braiding experiments covering a range of target angles. The achieved results highlight the model's accuracy and emphasize its potential to boost the efficiency and precision of overbraiding in industrial settings, thereby reducing the need for costly and time-consuming physical braiding iterations. • The study presents a hybrid kinematic-FEA model for overbraiding process simulation. • The modeling approach was applied to a complex, variable cross-section mandrel. • The model predictions were validated over a variety of target braid angles. • The proposed method enhances the accuracy and efficiency of overbraiding design.