Modeling and Verifying for Five‐Layer Interlocked 3D Braiding Geometries

ABSTRACT Regarding complex braiding geometric structures caused by cross layer interlocked behaviors in five‐layer interlocked 3D braiding thickness directions, alongside lacking complex mandrel geometric contour mapping mechanisms during braiding processes, this work conducts complex mandrel 3D braiding geometric modeling and validation research. Analyzing carrier arrangements clarifies fiber bundle interlayer interlocked patterns. Introducing segmented polar radius equations and characteristic movement matrices helps establish forward mathematical mapping models for fiber bundle spatial trajectories on multi characteristic complex mandrel surfaces, achieving yarn trajectory calculation and parametric reconstruction on mandrel surfaces. Concerning solid construction, constructing 3D standard orthogonal bases at trajectory points resolves fiber bundle solid distortion and interference challenges during sweeping processes. Multidimensional experimental validation demonstrates the established model matches actual braiding prototypes closely in fiber bundle spatial distribution, braiding angle variation laws, interlayer interlocked patterns, and cross section profile dimensions, with braiding angle errors remaining under 4% and cross section profile errors remaining under 2.5%. This method possesses excellent applicability for multiple complex mandrel 3D braiding geometric modeling, providing critical theoretical support for digital trajectory planning and molding control of complex irregular components.