Meso/macro-scale finite element model for forming process of woven fabric reinforcements

A meso/macro-scale finite element model is developed to analyze the three-dimensional forming process of woven fabric reinforcements. The yarns of reinforcements are considered as a transversely isotropic linear elastic material. The cross section and extrusion path of yarns are obtained by taking photographs from experimental samples. The present model evaluates the relative slippage and rotation at the crossover points of weft and warp, local stress and strain distributions in yarns at large deformation for different weave patterns. The meso/macro-scale finite element model is implemented to analyze the hemispherical forming of woven fabric and the results are compared to the experimental studies performed in the present study to verify the numerical procedure. Parametric study is conducted using the verified model to investigate the effects of blank holder load and different weave geometries. To evaluate the fiber rupture during forming process, the maximum axial stress is evaluated in the parametric study. Results show that the maximum tensile stress increases by the blank holder load and the twill 2/1 weave pattern has the highest maximum yarn tensile stress at the same forming conditions considered for fabrics with different weave patterns.