DigitPro – Digital Prototype Build-up Using the Example of a Braided Structure

Abstract

In this study, the development of a digital prototype on the example of a braided structure is presented. The different fields of engineering which have been considered are material design, manufacturing (braiding simulation & virtual infiltration) as well as structural analysis. Main goal of the digital prototype is to connect the various input- and output files of the software tools, to establish a user-friendly readability via a neutral, binary HDF5 file format as well as decreasing the cycle time during product design. On the basis of the example geometry a braiding mandrel concept was developed. A subsequent braiding simulation provided the fibre placement, the fibre orientations and the braiding path, which was transferred to a KUKA robot via a CAM interface for the actual manufacturing process. The braided structures were analysed with an automatic 3D preform analysis system, a 3D Measuring System (GOM ATOS Triple Scan) and CT-scans. The results were used for the virtual infiltration and for preform models, build with TexGen. These simulations were validated with experimental vacuum infusion tests, section cut specimen, ashing specimen and tensile coupon specimen.