Segmentation mapping and folding method of surfaces of revolution and its applications

Abstract

Purpose The purpose of this study was to develop a new folding method for modeling complicated folded fabric with surfaces of revolution. Design/methodology/approach Irregular wrinkles and mesh distortions easily appear in the fold modeling of a complex curved surface. Aimed at this key technical problem, the segmentation mapping folding method (SMFM) is proposed in this paper. First, high-precision flattened planes were obtained by using segmentation mapping techniques. Second, the segmented planes were transformed into a folded and continuous geometric model by using matrix transformations. Finally, initial stress was used to modify the geometric folding errors, which ensured agreement with the inflated flexible fabric’s geometry and the original design. Findings Compared with the traditional folding method, SMFM has the advantages of good finite-element mesh quality, large radial compression rate, regular folds, etc. The surface area error and the volume error of the inflated single torus established by SMFM were only 1.2 per cent, showing that SMFM has high modeling accuracy. The numerical results of an inflatable re-entry vehicle are presented to demonstrate the reliability, feasibility and applicability of SMFM. Moreover, the stress modification reduced the problems of stress concentration and mesh distortions, improving the accuracy and stability of the numerical calculations. Originality/value In this paper, for the first time, a folding method for modeling complicated folded fabric is proposed. This methodology can be used to model the multidimensional compression and regular folds of complex surfaces of revolution that cannot be flattened and to improve the accuracy and stability of the numerical calculations.