Finite element modelling of thermally bonded bicomponent fibre nonwovens: Tensile behaviour

Abstract Nonwovens are polymer-based engineered textiles with a random microstructure and hence require a numerical model to predict their mechanical performance. This paper focuses on finite element (FE) modelling the elastic–plastic mechanical response of polymer-based core/sheath type thermally bonded bicomponent fibre nonwoven materials. The nonwoven fabric is treated as an assembly of two regions having distinct mechanical properties: fibre matrix and bond points. The fibre matrix is composed of randomly oriented core/sheath type fibres acting as load-transfer link between bond points. Random orientation of individual fibres is introduced into the model in terms of the orientation distribution function (ODF) in order to determine the material’s anisotropy. The ODF is obtained by analysing the data acquired with scanning electron microscopy (SEM) and X-ray micro computed tomography (CT). On the other hand, bond points are treated as a deformable bicomponent composite material composed of the sheath material as matrix and the core material as fibres having random orientations. An algorithm is developed to calculate the anisotropic material properties of these regions based on properties of fibres and manufacturing parameters such as the planar density, core/sheath ratio and fibre diameter. Having distinct anisotropic mechanical properties for two regions, the fabric is modelled with shell elements with thicknesses identical to those of the bond points and fibre matrix. Finally, nonwoven specimens are subjected to tensile tests along different loading directions with respect to the machine direction of the fabric. The force–displacement curves obtained in these tests are compared with the results of FE simulations.