Full-field fiber trajectory motion simulation and distribution verification of complex components based on three-dimensional winding technology

As an emerging composite preform manufacturing technology, three-dimensional winding technology can solve the problem of large-angle fiber placement for complex core molds and make circular winding for core molds with arbitrary shapes within a certain length by robot-assisted winding. However, the control method of 3D winding is still immature, the winding trajectory of the shaped core mold is complicated, and the resulting fiber structure is difficult to predict. After the study of 3D winding fiber deposition process, the kinematic simulation method was used to establish a 3D winding simulation model to realize the fast prediction of 3D winding fiber structure. Firstly, the mesh reconstruction of the shaped mandrel was carried out to improve the accuracy of the simulation; then the spatial discrete point positions were used to simulate the motion trajectory of the filament nozzle around the complex mandrel, and finally the fiber deposition mechanism was used as a criterion to achieve the iterative updating of the simulated fiber structure. The 3D winding simulation model has two main control parameters: the step and the deflection angle of the rotary head. It is verified through experiments that the surface density of the mandrel decreases when the step increases, and the dynamic deflection of the rotary head directly affects the inner and outer fiber structure of the curved mandrel. The experiment results obtained from the simulation of the straight mandrel are compared with the theoretically calculated values, and the error is less than 0.2%. The reliability and accuracy of the kinematic simulation method for the simulation of 3D winding technology is proved by the combination of theoretical and practical research.