Finite element analysis of penetration force for needle during tufting process

Abstract

Tufted carpet is one of the most used carpets. The penetration force of needle is an important factor in tufting process. Few know how to calculate the penetration force during the tufting, although the principle is one of the least understood processes. This paper presents our research on using finite element method (FEM) to study the penetration force of needle during tufting. In this study, the model is developed using ABAQUS software, and the material properties of nonwoven fabric are approximately modeled by linear elastic orthogonal anisotropic continuum. The required engineering constants were obtained from experimental test. A user-defined subroutine VUMAT for characterizing the constitutive relationship of the orthogonal anisotropy nonwoven fabric and the damage evolution was compiled and connected with a commercial software package ABAQUS/Explicit to calculate the penetration force. At the same time, needle penetration force was tested by sensor mounted on needle bar of tufting machine. It was found that there is an approximate agreement of the penetration force between FEM calculations and experimental results. The reasonable agreement proves the validity of finite element analysis model, which could be used to calculate the impact response of the needle penetration stress precisely. The finite element model has been verified experimentally and can be used to study the influence of the key tufting parameters such as the backing material properties and the needle geometry on penetration force, which is vital for designing needle and driving mechanism.