Wrinkling, a common manufacturing-induced defect, can be delayed in dry woven fabrics by applying tension during processing. Such a known solution in industrial practice, is still not sufficiently implemented in the modeling and simulation of woven fabrics. This study proposes a new constitutive model considering fabric’s inherent coupling, non-orthogonality, and non-linearity. First, the intrinsic coupling in question is distinguished from the typical coupling presented by the Hook’s law. Then, the most influential forms of coupling are chosen and introduced to the model. Moreover, via experimental evidence, we reveal that the concept of inherent coupling raises a new issue: the load history dependency of the fabric. Accordingly, the base model was evolved to a hypoelastic form to capture this dependency. The stiffness functions of the introduced model are determined, considering the mechanical behavior of a typical polypropylene (PP)/glass plain weave and the underlying meso-scale sources of the coupling. An inverse method was employed to identify the unknown model parameters. While the basic loading modes such as the uniaxial tension and picture frame tests are utilized for model calibration, the more complex loading conditions such as the simultaneous biaxial tensile-shear test, which would be more comparable to actual forming processes, are selected as the independent datasets to validate accuracy of the model. Comparisons with the experimental results demonstrated that the coupled model predicts the behavior of the fabric more accurately than the uncoupled model.
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