Aerodynamic web forming: process simulation and material properties

In this paper we present a chain of mathematical models that enables the numerical simulation of the airlay process and the investigation of the resulting nonwoven material by means of virtual tensile strength tests. The models range from a highly turbulent dilute fiber suspension flow to stochastic surrogates for fiber lay-down and web formation and further to Cosserat networks with effective material laws. Crucial is the consistent mathematical mapping between the parameters of the process and the material. We illustrate the applicability of the model chain for an industrial scenario, regarding data from computer tomography and experiments. By this proof of concept we show the feasibility of future simulation-based process design and material optimization which are long-term objectives in the technical textile industry.