Yarn level finite element method simulation for bending over sheaves of braided ropes

The complex problem of ropes (cyclic) bending over sheaves (CBOS) is considered in this article. Ropes that are used to manoeuvre and regulate sails undergo a variety of dynamic stresses which are crucial yet difficult to determine, due to the complexity of the multi-scaled braiding structure of ropes. A full dynamic Finite Element Method (FEM) simulation of a braided rope bending over a sheave is conducted with the commercial software Abaqus/Explicit, as it can capture the complex processes occurring inside the rope to high accuracy. A theoretical deduction is performed to determine the yarn paths in a 3D braided structure. Relative movement between braided yarns (including the interlacing point) are better assessed at yarn level through 3D element types instead of the traditional beam elements, as they allow to obtain an estimation of yarn-yarn displacement. Parametric studies are conducted to better understand the factors that affect the yarn sliding. The ratio between the diameter of the sheave and the rope, and the braiding angle, are found to be crucial for the relative movement, while the number of yarns and their diameters have little influence. The successful simulation process demonstrates the feasibility of modelling and analysing the complex interaction occurring in braided structures under specific boundary conditions. The calculated estimated displacement can contribute to further investigations such as the friction and heat generation problem in braided ropes. Simulation with this method can provide alternatives in predicting lifespan of braided products that cannot be easily inspected.