Effect of the frictional coefficient and pre-tension on stress distribution of fabric during the weaving process

Abstract

The non-uniform stress distribution of woven fabric has a significant influence not only on its mechanical performance in service, but also on its weaving efficiency in the fabrication process. For investigating the stress distribution in woven fabric, a numerical model at the yarn scale was established to simulate the interlacing process between the weft and warp yarns using an explicit finite element solver. The yarns were assumed to be a homogeneous continuum and the transversal isotropic constitutive equation was used. A modified lenticular initial shape was used as the cross-section of the yarn and trajectories of warp and weft yarns were set to be straight. The classical Amonton–Coulomb law was used for the tangential behavior between the weft and warp yarns. The simulation results reveal that the interaction between weft and warp yarns consists of three phases in terms of contact, adhesion and sliding. The sectional stress distribution in the weft yarn determined by multi-points contact between a single weft yarn and a group of warp yarns was also analyzed. The tension stress of the weft yarn was larger in the middle part than that in both sides. Based on the numerical model, the effects of two key parameters, namely the frictional coefficient and weft pre-tension, on the stress distribution were discussed in detail. The weft crimp angle and warp tension distribution uniformity decreased as the frictional coefficient decreased, whereas the warp tension fluctuation range did not obviously decrease. However, an improved method by exerting pre-tension in two ends of weft yarn was proposed and the warp tension fluctuation range was significantly decreased. The distribution trend of warp tension obtained from the numerical simulation showed an acceptable tendency with experiment measurements.