The braiding angle of a steel wire braided hose is one of the core parameters in its structural design, directly affecting its compressive and torsional resistance. Adjusting the braiding angle requires a synergistic consideration of mechanical principles and actual working conditions. By balancing the circumferential and axial stress distribution, the hose's performance under complex stress environments is improved.
From the perspective of compressive resistance, the braiding angle determines the steel wire layer's resistance to internal pressure. When the hose is subjected to internal pressure, the steel wire layer needs a reasonable angle design to convert circumferential stress into tensile or shear stress in the wires. If the braiding angle is close to the theoretical neutral angle, the steel wire layer experiences almost no significant change in length or diameter under internal pressure, thus avoiding stress concentration due to excessive deformation. For example, when using a braiding angle close to 54°44', the circumferential and axial strength of the steel wire layer are relatively balanced, allowing the hose to maintain structural stability under high pressure. If the angle deviates from the neutral angle, such as increasing it to nearly 90°, the steel wire layer will primarily bear circumferential tensile stress. While this can increase burst pressure, it may lead to excessive elongation of the steel wire braided hose due to insufficient axial strength. Conversely, if the angle is too small, it may cause diameter expansion, reducing the compressive strength limit.
Optimizing torsional performance requires attention to the influence of the braiding angle on torsional stiffness. When the steel wire braided hose is subjected to torque, the braiding angle of the steel wire layer determines its ability to resist torsional deformation. When the angle is small, the axial component of the steel wire increases, and the hose is prone to large shear deformation during torsion, resulting in a decrease in torsional strength. When the angle is large, the circumferential component of the steel wire is enhanced, which can improve torsional stiffness, but may reduce flexibility due to excessive structural rigidity. Therefore, it is necessary to determine the optimal angle range through experiments or simulations so that the steel wire layer can effectively transmit torque during torsion while dispersing stress through reasonable deformation to avoid localized failure. For example, when using a multi-layered cross-braided structure, the braiding angles of the inner and outer layers can complement each other. The inner layer provides basic torsional support, while the outer layer enhances overall stiffness through angle adjustment, thereby improving the overall torsional resistance of the steel wire braided hose.
Adjusting the braiding angle also requires considering the synergistic effect of wire diameter, number of layers, and braiding density. At the same braiding angle, increasing the wire diameter or the number of braided layers can improve the compressive and torsional resistance of the steel wire braided hose, but may sacrifice flexibility. Increasing the braiding density can enhance the friction between the wires and improve stress transfer efficiency, but excessive tightness should be avoided to prevent increased manufacturing difficulty or cost. Therefore, optimizing the braiding angle requires comprehensive matching with other parameters. For example, a smaller angle and multiple layers of wire can be used in high-pressure applications, while a larger angle and single-layer wire configuration can be selected in scenarios requiring high flexibility.
In practical applications, adjusting the braiding angle also needs to be combined with the specific operating conditions of the hose. For example, in hydraulic systems, hoses need to withstand high-frequency pressure pulses and small-amplitude torsion. In this case, the braiding angle should be biased towards a neutral angle to balance compressive strength and fatigue resistance. In scenarios requiring frequent bending, the angle can be appropriately increased to improve flexibility, while optimizing the steel wire material or surface treatment enhances wear resistance. Furthermore, factors such as ambient temperature and media corrosivity can also affect the choice of braiding angle, requiring comprehensive consideration during the design process.
Adjusting the braiding angle of steel wire braided hoses must be based on mechanical principles. By balancing circumferential and axial stresses, optimizing torsional stiffness, and coordinating with other structural parameters, a comprehensive improvement in compressive and torsional resistance can be achieved. This process requires combining theoretical calculations, experimental verification, and practical application scenarios to ensure the hose maintains reliability and durability under complex operating conditions.
