A comparative study of emerging material point method and FEM for forming simulation of textile reinforcements

Abstract

For forming simulations of fabric composites, nonlinear Finite Element Method/FEM has been a long-standing tool to predict and mitigate defects such as wrinkling. However, small-time step requirements in explicit FEM codes, numerical instabilities, and large computational time are among challenges reported. This study presents an alternative fast forming simulation technique through an application of the so-called Material Point Method/MPM, which enables the use of much larger time steps along with fewer numerical instabilities. As a preliminary step towards assessment of this method, both standard 2D deformation modes and 3D hemispherical forming setups were employed, using a plain fabric weave at dry condition. The MPM results were compared to the conventional FEM simulations, as well as to the physical experiments. Notably, the MPM method showed a runtime 20 times faster than its FEM counterpart (under a comparable mesh size), yet with the same reliability in forming predictions as verified by experiments.