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Research Papers: Design Automation

The Design of Optimal Lattice Structures Manufactured by Maypole Braiding

[+] Author and Article Information
Austin Gurley

Department of Mechanical Engineering,
Auburn University,
1418 Wiggins Hall,
Auburn, AL 36849
e-mail: arg0007@auburn.edu

David Beale

Professor
Mem. ASME
Department of Mechanical Engineering,
Auburn University,
1418 Wiggins Hall,
Auburn, AL 36849
e-mail: bealedg@auburn.edu

Royall Broughton

Professor Emeritus
Department of Polymer and
Fiber Engineering,
Auburn University,
115 Textile Building,
Auburn, AL 36849
e-mail: brougrm@auburn.edu

David Branscomb

Research Specialist
Composite Structures,
Takata Highland,
1350 Bridgeport Drive, Suite 1,
Kernersville, NC 27284
e-mail: david.branscomb@takata.com

lCorresponding author.

Contributed by the Design Automation Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received February 10, 2015; final manuscript received July 15, 2015; published online August 6, 2015. Assoc. Editor: Nam H. Kim.

J. Mech. Des 137(10), 101401 (Aug 06, 2015) (8 pages) Paper No: MD-15-1082; doi: 10.1115/1.4031122 History: Received February 10, 2015

Beginning with the maypole braiding process and its inherent constraints, we develop a design methodology for the realization of optimal braided composite lattice structures. This process requires novel geometric, mechanical, and optimization procedures for comprehensive design-ability, while taking full advantage of the capabilities of maypole braiding. The composite lattice structures are braided using yarns comprised of multiple prepreg carbon fiber (CF) tows that are themselves consolidated in a thin braided jacket to maintain round cross sections. Results show that optimal lattice-structure tubes provide significant improvement over smooth-walled CF tubes and nonoptimal lattices in torsion and bending, while maintaining comparable axial stiffness (AE).

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Figures

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Fig. 1

Maypole braiding open-structure composites

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Fig. 2

Kinematic equations replicate braiding machine motion from key machine variables

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Fig. 3

Three stages of the geometry modeling process: (a) kinematics, (b) compression, and (c) tension

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Fig. 4

Example of joint-intersection beam elements

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Fig. 5

Major design variables of the optimal braided lattice structure. The base true triaxial sample was manufactured for model validation.

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Fig. 6

Optimal braided lattice geometries: (a) optimal strut, (b) optimal driveshaft, (c) optimal boom, and (d) optimal bridge

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