A matrix computing method for visualizing switchless controlled 3D hexagonal‐annular rotary braiding process architecture

Abstract Numerous process architectures for fabric molding are investigated because fiber braided structure is closely related to the performance of fiber‐reinforced composites. However, existing methods for calculating process architectures have to deal with the coordinates of each fiber when modeling the three‐dimensional braiding method without individually controlled switches. The amount of data grows geometrically as the number of fibers and braiding steps increases. A methodology that enables simple and efficient computation of a model of the relationship between braiding parameters and fiber structure is urgently needed. This paper proposes a novel algorithm to trace the yarn carrier trajectories through machine simulation with Euler rotation‐matrix operations. To predict the real fabric architecture, a contraction factor is introduced to optimize the yarn trajectory while considering the volume of the yarn. The optimized fabric architecture is explored and the braiding process architecture with different braiding parameters is simulated according to the algorithm. Based on the exploration of the relationship between the braiding parameters and the process structure, a hexagonal‐annular braiding machine was established, which can fabricate fabrics with different cross‐sectional shapes. The simulation results were verified by the braiding experiments.